Linked PDF

D35, DX35, D40, DX40,
D45, DX45
REPAIR MANUAL
COMPLETE CONTENTS
SECTION 00 - GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 18 - CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 21 - TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SECTION 23 - DRIVELINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SECTION 25 - FWD FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SECTION 27 - DIFFERENTIAL, REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 29 - HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 17
SECTION 31 - POWER TAKE-OFF (PTO) SYSTEMS . . . . . . . . . . . . . . . . . . . . 21
SECTION 33 - BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 41 - STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SECTION 44 - 2WD FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 50 - CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SECTION 55 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 90 - PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
The following pages are the collation of the contents pages from each section and
chapter of the D35 -- DX45 Repair manual. Complete Repair part # 87622993.
The sections used through out all Case IH product Repair manuals may not be used for
each product. Each Repair manual will be made up of one or several books. Each book
will be labeled as to which sections are in the overall Repair manual and which sections
are in each book.
The sections listed above are the sections utilized for the D35 -- DX45 Tractors, PIN
number HBA015001 and above.
© 2006 CNH America LLC 87622995 12/06
Printed In U.S.A. Replaces 87056694
SECTION 00 - GENERAL INFORMATION
BOOK 1 - 87056690
Chapter 1 - General Information

CONTENTS
Section Description Page

00 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Decals -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instruction Decals -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Decals -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Instruction Decals -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
International Symbols -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Specifications -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Dimensions -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specifications -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General Dimensions -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Tire Inflation Pressure -- Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
00 100 Pre-Season and Pre-Delivery Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2
SECTION 10 - ENGINE
BOOK 1 - 87056690
Chapter 1 - Engine
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Metric Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compression Test and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cylinder Head and Valve Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cylinder Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Separating the Tractor at the Clutch Housing/Engine -- 12 x 12 Transmission . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Separating the Tractor at the HST Housing/Engine -- HST Transmission . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Separating the Tractor at the Engine Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Attaching the 12 x 12 Transmission to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Attaching the HST to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel Injector and Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Temperature Sending Switch and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fan, Water Pump and External Oil Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Air Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rocker Arm Shaft and Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10 101 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3
SECTION 10 - ENGINE
BOOK 1 - 87056690
Chapter 1 - Engine (Continued)

CONTENTS

Valve Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fuel Shutoff Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10 106 Engine Timing Gear Cover, Timing Gears and Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . 57
Timing Gear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10 106 Timing Gears and Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10 102 Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Oil Suction Pipe and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10 110 Balancer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10 105 Connecting Rods, Bearings and Pistons, Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10 103 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 103 Backplate and Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Crankshaft and Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 101 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4
SECTION 10 - ENGINE
BOOK 1 - 87056690

CONTENTS

Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10 105 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Clearance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Pistons, Rings and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 103 Crankshaft -- Main Bearing and Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Removal and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Bearing (Bushing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10 106 Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10 103 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10 102 Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10 102 Front Oil Seal and Steering Pump Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10 103 Crankshaft and Bearing Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Rear Oil Seal and Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
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SECTION 10 - ENGINE
BOOK 1 - 87056690

CONTENTS

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10 105 Pistons and Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Balancer Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Oil Suction Pipe and Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10 106 Camshaft and Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10 106 Idler Gear, Oil Pump and Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Hydraulic Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10 101 Head Gasket Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10 106 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
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SECTION 10 - ENGINE
BOOK 1 - 87056690

CONTENTS

Water Pump and Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
External Oil Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Glow Plug and Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 218 Fuel Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Alternator and Temperature Sender Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10 304 Description of Operation -- Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10 206 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Construction and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10 304 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10 400 Description of Operation -- Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10 402 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
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SECTION 10 - ENGINE
BOOK 1 - 87056690

CONTENTS

10 402 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10 414 Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Overhaul -- Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10 406 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10 402 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10 402 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
SECTION 10 - ENGINE
BOOK 1 - 87056690
Chapter 2 -- Fuel Systems

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standards for Adjusting Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
10 242 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
8
SECTION 10 - ENGINE
BOOK 1 - 87056690
Chapter 2 -- Fuel Systems (Continued)

CONTENTS

Troubleshooting -- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting -- Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting -- Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10 244 Fuel Variation Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Delivery Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 244 CTD (Compact Timing Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 236 Pumping Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 214 Delivery Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 242 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calibration/Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 230 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spill-Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel Screw/High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 230 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Auto Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10 230 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10 218 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Assembly/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine Breather Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Troubleshooting -- Engine Breather Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9
SECTION 18 - CLUTCH
BOOK 1 - 87056690
Chapter 1 -- Clutch
CONTENTS

18 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Separating the Tractor at the Clutch Housing/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
18 110 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
18 110 Clutch Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pilot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Damper Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Flywheel Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clutch Release Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Clutch Linkage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
18 100 Cross Shaft Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
10
SECTION 18 - CLUTCH
BOOK 1 - 87056690
Chapter 1 -- Clutch (Continued)

CONTENTS

Pedal Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maximum Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 21 - TRANSMISSION
BOOK 2 - 87056691
Chapter 1 - 12 x 12 Synchronized Shuttle Shift Gear Transmission

CONTENTS

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Metric Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cross Section -- 12 x 12 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powerflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 114 Separating the Tractor at the Clutch Housing/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 110 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
11
BOOK 2 - 87056691

(Continued)
CONTENTS

21 148 63 Retainer Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
21 148 63 Main Shift Rails and Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
21 148 63 Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
21 148 63 Range Shift Rail and Shift Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
21 148 63 Range Gear Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
21 148 63 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
21 148 63 Reverse Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
21 148 63 Shuttle Shift Rail and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
21 148 63 Main Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
21 148 63 Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
12
BOOK 2 - 87056691

(Continued)
CONTENTS

Main Transmission Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Main Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Shuttle Shift Rail and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Reverse Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
21 148 63 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
21 148 63 Main Countershaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
21 148 63 Range Shift Rail and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
21 148 63 Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 148 63 Main Shaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
21 148 63 Main Shaft Gears End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Main Shift Rails and Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Retainer Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
21 110 10 Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
21 130 Transmission Shift Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
13
BOOK 2 - 87056691

(Continued)
CONTENTS

Main Shift Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Shuttle Shift Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
SECTION 23 - DRIVELINE
BOOK 2 - 87056691
Chapter 1 - Driveline
CONTENTS

23 000 Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front Wheel Drive Take Off Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
14
SECTION 25 - FWD FRONT AXLE
BOOK 2 - 87056691
Chapter 1 - FWD Front Axle

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front to Rear Axle Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
25 100 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
FWD Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lubricate Every 50 Hours -- Standard FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Standard FWD Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
25 108 Gear Reduction Drop Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
25 102 Front Axle and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Gear Reduction -- Drop Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Axle and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Differential Case Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Check and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Ring Gear-to-Pinion Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Chapter 1 - FWD Front Axle (Continued)

CONTENTS

25 108 Gear Reduction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Bevel Gear-to-Pinion Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 27 - DIFFERENTIAL, REAR AXLE

BOOK 2 - 87056691
Chapter 1 - Differential, Rear Axle

CONTENTS

27 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
27 110 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
27 110 Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
27 126 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
27 106 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Chapter 1 - Differential, Rear Axle (Continued)

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Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
27 126 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
27 126 Final Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SECTION 29 -- HYDROSTATIC TRANSMISSION

BOOK 3 - 87056692
Chapter 1 -- Hydrostatic Transmission

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Forward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reverse Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
29 212 Variable Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
29 212 Two Position Displacement Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
29 134 Hi/Lo Speed Control/Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hi/Lo Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
29 200 Foot Control Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Charge Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Testing and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hi/Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Separating the Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DX35, DX40, and DX45 w/HST Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Separating at the HST Housing/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Separating the HST Housing at the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Attaching the HST Housing to the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Attaching the HST to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
29 202 Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
29 130 Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Motor Swash Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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CONTENTS

Input and Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pump Swash Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
29 130 Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Swash Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pump Shaft (Input Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
29 218 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly for Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Motor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
29 218 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly for Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
29 130 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
29 204 Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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CONTENTS

Description of Operation -- Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
29 300 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gearbox Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Overhaul -- Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
29 214 Hi/Lo Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adapter Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Electromagnet Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
20
BOOK 3 - 87056692
Chapter 2 -- Adjustment
CONTENTS

HST Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HST Cruise Control Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
29 200 HST Foot Control Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HST Pedals Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 31 -- POWER TAKE-OFF (PTO) SYSTEMS

BOOK 3 - 87056692
Chapter 1 -- Power Take-Off (PTO) Systems

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PTO Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
31 110 Rear PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Flow Diagram for the 12 x 12 Synchronized Shuttle Shift Transmission . . . . . 7
Power Flow Diagram for the Hydrostatic Transmission (HST) . . . . . . . . . . . . . . . . . . 8
31 120 Power Flow Diagram for Tractors Equipped with a Mid PTO Kit . . . . . . . . . . . . . . . . 9
31 104 Hydraulic Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PTO Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21
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Chapter 1 -- Power Take-Off (PTO) Systems (Continued)

CONTENTS

Test Procedure (Below Serial Number -- See Chart) . . . . . . . . . . . . . . . . . . . . . . . . 14
Test Procedure (Serial Number and Above -- See Chart) . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
31 104 82 PTO System Diverter Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
31 104 82 PTO Clutch Control Valve (BSN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clutch Control Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
31 104 82 PTO Clutch Control Valve (ASN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
31 114 62 PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
31 114 68 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
31 114 62 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
31 114 42 Power Take Off System System for 12 x 12 Synchronized Shuttle Shift Transmission . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
22
BOOK 3 - 87056692
Chapter 1 -- Power Take-Off (PTO) Systems (Continued)

CONTENTS

PTO Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
31 114 46 PTO Countershaft and Rear PTO Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
31 114 46 Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
31 114 00 PTO System for Hydrostatic Transmission (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
31 114 42 PTO Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
31 114 42 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
31 114 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
31 120 00 Mid PTO Countershaft and Drop Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
23
SECTION 33 - BRAKES
BOOK 3 - 87056692
Chapter 1 -- Brakes
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
33 120 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
33 110 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
33 120 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 35 -- HYDRAULIC SYSTEM

BOOK 3 - 87056692
Chapter 1 -- Hydraulic System

CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flow Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
35 080 Combination System Relief -- Diverter Valve Manifold Assembly . . . . . . . . . . . . . . . . . 10
35 200 Control Valve Assembly (HPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
35 210 Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
35 210 Raising Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 210 Lowering Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
24
BOOK 3 - 87056692
Chapter 1 -- Hydraulic System (Continued)

CONTENTS

35 200 Bypass Spool -- Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Closed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
35 200 Open Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
35 183 Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
35 108 Single Lever -- Position Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
35 108 Neutral Position to Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Raise Position to Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Neutral Position to Lowering Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
35 112 Dual Lever Position Control (Draft Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Top Link Sensing Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Top Link Sensing Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Varying Draft Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
35 124 Combining Position and Draft Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inlet Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Overhaul -- Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
35 110 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
35 200 Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
25
BOOK 3 - 87056692

CONTENTS

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
35 180 Combination System Relief Valve and Diverter Valve Assembly . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
35 182 PTO System Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
35 124 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
HPL Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Description of Operation -- Hydraulic Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
35 304 Hydraulic Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
35 304 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
35 300 Sump Tube and Screen Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
26
BOOK 3 - 87056692

CONTENTS

Description of Operation -- Remote Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
35 204 Remote Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Rear (Single-Spool) Remote Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Front (Double-Spool) Remote Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rear (Single-spool) Remote System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Remote Cylinder Extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Remote Cylinder Retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Front Remote (Two Spool) Loader Control Valve Fluid Flow Diagrams . . . . . . . . . . . . . . . 65
Bucket Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Neutral/Lift Control-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Dumping/Lift Control-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Dumping REGEN/Lift Control-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Roll Back/Lift Control-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Neutral/Lift Control-Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Neutral/Lift Control-Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Neutral/Lift Control-Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
35 204 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Front (Double Spool) Remote Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
27
SECTION 41 - STEERING
BOOK 4 - 87056693
Chapter 1 -- Steering
CONTENTS

41 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
41 206 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 216 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 216 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 200 Power Steering Operation -- 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Flow -- Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
41 200 Fluid Flow -- Left Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
41 200 Fluid Flow -- Right Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
41 200 Manual Operation -- 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump, Steering Motor, and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
41 204 Steering Control Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
41 216 Steering Cylinder -- FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
41 216 Steering Cylinder -- 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
41 216 Steering Cylinder -- 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
28
BOOK 4 - 87056693
Chapter 1 -- Steering (Continued)

CONTENTS

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
41 206 Pump and Reservoir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
41 206 Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SECTION 44 - 2WD FRONT AXLE

BOOK 4 - 87056693
Chapter 1 - 2WD Front Axle

CONTENTS

44 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
44 103 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
29
SECTION 50 -- CLIMATE CONTROL
BOOK 4A - 87622994
Chapter 1 -- Climate Control --

DX40--DX45 With Cab
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Receiver/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HVAC Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning Cab Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compressor Protection Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High-Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low-Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab and Engine Bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Expansion Valve -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Temperature/Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preventing Mixing of Service Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
30
BOOK 4A - 87622994

DX40--DX45 With Cab (Continued)
CONTENTS

Refrigerant Extraction and Recycling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Using Extraction Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Using Recycling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Recycling vs. Reclaiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Containment of Air Conditioning Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Recharging/Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Using a Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Checking Refrigerant for Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Containers for Storing Recycled Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disposal of Empty or Near-empty Disposable Containers . . . . . . . . . . . . . . . . . . . 22
Applicable SAE Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Related SAE Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Manifold Gauges and Interpretations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Performance Test Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Evacuating the Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
HVAC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
31
BOOK 4A - 87622994

CONTENTS

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Receiver/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Evaporator/Heater Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Blower Motor/Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Compressor Assembly Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compressor Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Clutch Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
32
BOOK 4A - 87622994

CONTENTS

Compressor Repaired Internally and Reinstalled in the System . . . . . . . . . . . . . . 67
Sanden Compressor Replaced by a New Sanden Compressor
of the Same Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Clutch Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Keyed Shaft Armature Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Rotor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Field Coil Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Field Coil Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rotor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Armature Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacement of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Valve Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Valve Plate and Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
33
SECTION 55 - ELECTRICAL SYSTEM
BOOK 4 - 87056693
Chapter 1 -- Electrical
CONTENTS

Component Location and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
55 100 Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Checking the Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Terminal Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Stop Position (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Heat/Accessory/Run Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Start Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Light Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Light Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
“Off” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
“Taillight/Instrument Panel” Position (middle position) . . . . . . . . . . . . . . . . . . . . . . . 18
“Headlight Position” (forward position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Light Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
55 404 Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
55 404 Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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BOOK 4 - 87056693
Chapter 1 -- Electrical (Continued)

CONTENTS

Hazard Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
“Off” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
“On” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
55 408 Transmission Range Safety Switch (HST and Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Extended Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Retracted Position (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
55 408 Rear (Main) PTO Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Retracted Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
55 408 Mid PTO Safety Switch (Optional for DX35, DX45 and DX40 Models Only) . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
55 408 Seat Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
55 408 Parking Brake Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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CONTENTS

Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
(DX) Series Relay Panel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
(D) Series Relay Panel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Testing-Micro Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
“HI”, “LOW”, Cruise Control, Fuel Shutoff, PTO Safety, and Glow Plug Lamp Relays . . 35
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Headlight and Neutral Start Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Glow Plug Power Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Module Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Operator Safety Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Glow Plug Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
55 201 Engine Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hazard Flasher/Turn Signal Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
55 410 Fuel Level Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
55 414 Engine Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Engine Coolant Temperature Sending Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hi/Low Transmission Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Optional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Hi/Low Transmission Range Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Electric Cruise Control Switch (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cruise Control Magnet (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Cruise Control Brake Release Switch (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Extended Position (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
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BOOK 4 - 87056693
Chapter 2 -- Schematics
CONTENTS

Complete Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Start Circuit (Operator Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Start Circuit (Operator Not Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safe Operation Circuit (Operator Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safe Operation Circuit (Operator Not Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Glow Plug Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Road Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hazard Flasher Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Right Turn Signal Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Left Turn Signal Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
PTO Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine Coolant Temperature Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Engine Low Oil Pressure Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel Level Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Parking Brake Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Tachometer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Auxiliary Power Socket Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Cruise Control Circuit (HST Transmission) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
HST Range “LOW” Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
HST Range “HIGH” Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
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BOOK 4 - 87056693
Chapter 3 - Instrument Panel

CONTENTS

Component Operation and Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Component Testing and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instrument Panel Indicator and Illumination Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bulb Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
39
BOOK 4 - 87056693
Chapter 4 - Alternator and Starter

CONTENTS

Alternator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Alternator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Principle of IC Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Preliminary Alternator Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alternator Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Alternator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Alternator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Alternator Component Testing and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Alternator Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Alternator Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Alternator Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Alternator Bench Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Starter Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Starter Motor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Starter Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Starter Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
40
BOOK 4 - 87056693
Chapter 4 - Alternator and Starter (Continued)

CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Electrical Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
41
SECTION 55 -- ELECTRICAL
BOOK 4A - 87622994
Chapter 5 -- Electrical --
DX40--DX45 With Cab
CONTENTS

Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuse Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Heat/ Accessory/ Run Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Start Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Multifunction Stalk Switch (Lights, Turn Signals, Horn) . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
55 404 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
55 404 Taillight/Rear Flasher Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front Flasher Warning Light/Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cab Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
42
BOOK 4A - 87622994
CONTENTS

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
“Off” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
“On” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
55 408 Transmission Range Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Extended Position (PTO “ON”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Retracted Position (PTO “OFF”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
55 408 Mid PTO Safety Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
43
BOOK 4A - 87622994
CONTENTS

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
(DA) Series Relay Panel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
“HI”, “LOW”, Cruise Control, Fuel Shutoff, PTO Safety, Glow Plug Lamp,
Flasher Cutoff, Park Brake Interface, Front Work Lights, and HVAC Relays . . . . . . . . . . 33
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Headlight, Neutral Start, and Cab Power Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation (All Relays) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Module Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Park Brake Safety Alarm (Buzzer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Glow Plug Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
44
BOOK 4A - 87622994
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hi/Low Transmission Range Switch (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Optional Joystick Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hi/Low Transmission Range Solenoid (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
45
BOOK 4A - 87622994
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cab to Tractor Harness Main Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
46
BOOK 4A - 87622994
Chapter 6 -- Schematics --
DX40--DX45 With Cab
CONTENTS

Electrical Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Start Circuit (Operator Present or Not Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safe Operation Operator Present Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Safe Operation Operator Not Present Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Safety Alarm Circuit (Key “Off” and Park Brake “Off”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Safety Alarm Circuit (Key “On”, Rear PTO “On”, Operator Not Present and
Park Brake “On”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Park Brake “Off”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Headlights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cab Work Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Interior Cab Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hazard Flasher Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
HVAC Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Front and Rear Wiper Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Horn Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
HST Range “Low” Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
HST Range “High” Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
PTO Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Park Brake Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Coolant Temperature Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Engine Low Oil Pressure Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Fuel Level Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Tachometer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Beacon Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Radio Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
47
BOOK 4A - 87622994
Chapter 7 -- Instrument Panel --

DX40--DX45 With Cab
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Proof Meter (hour meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instrument Panel Indicator and Illumination Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bulb Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
48
BOOK 4A - 87622994
Chapter 8 -- Alternator and Starter --

DX40--DX45 With Cab
CONTENTS

Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
49
BOOK 4A - 87622994

CONTENTS

Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
50
SECTION 90 - PLATFORM
BOOK 4 - 87056693
Chapter 1 - Platform
CONTENTS

90 105 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
90 100 Rear Hood Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
90 110 Dash Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
90 120 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
90 114 ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
90 116 D35, D40, D45 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
90 116 DX35, DX40, DX45 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
D35, D40, D45 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
51
BOOK 4 - 87056693
Chapter 1 - Platform (Continued)

CONTENTS

DX35, DX40, DX45 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
90 115 D35, D40, D45 Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
90 115 DX35, DX40, DX45 Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
90 115 D35, D40, D45 Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
90 115 DX35, DX40, DX45 Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
BOOK 4A - 87622994
Chapter 2 - Platform --
DX40--DX45 With Cab
CONTENTS

Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear Hood Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dash Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
52
BOOK 4A - 87622994
CONTENTS

Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Door Handle and Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Door Striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cab Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
53
BOOK 4A - 87622994
CONTENTS

Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cab Lifting Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
54
SECTION 00 - GENERAL INFORMATION - CHAPTER 1
SECTION 00 - GENERAL INFORMATION
Chapter 1 - General Information
CONTENTS

00 000 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Decals -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instruction Decals -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety Decals -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Instruction Decals -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
International Symbols -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Specifications -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General Dimensions -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Specifications -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General Dimensions -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Recommended Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Tire Inflation Pressure -- Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
00 100 Pre-Season and Pre-Delivery Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
00-1
INTRODUCTION
This repair manual provides the technical informa- On Case IH equipment, left and right are determined
tion needed to properly service the Case IH D35, by standing behind the unit, looking in the direction
DX35, D40, DX40, D45 and DX45 tractors. Use this of travel.
manual in conjunction with the operator’s manual for
complete operation, adjustment, and maintenance
information.
00-2
PRECAUTIONARY STATEMENTS
PERSONAL SAFETY
Throughout this manual and on machine decals, you will find precautionary statements (“CAUTION”,
“WARNING”, and “DANGER”) followed by specific instructions. These precautions are intended for the personal
safety of you and those working with you. Please take the time to read them.
CAUTION
The word “CAUTION” is used where a safe behavioral practice according to operating and maintenance
instructions and common safety practices will protect the operator and others from accident
involvement.
DANGER
The word “DANGER” denotes a forbidden practice in connection with a serious hazard.
WARNING
The word “WARNING” denotes a potential or hidden hazard which has a potential for serious injury. It
is used to warn operators and others to exercise every appropriate means to avoid a surprise
involvement with machinery.
FAILURE TO FOLLOW THE “CAUTION”, “WARNING”, AND “DANGER” INSTRUCTIONS MAY RESULT IN
SERIOUS BODILY INJURY OR DEATH.
MACHINE SAFETY
The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for
machine safety.
IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent
minor machine damage if a certain procedure is not followed.
00-3
TECHNICAL INFORMATION
HARDWARE
GENERAL Approximately 90% of the torque applied during
The D35, DX35, D40, DX40, D45 and DX45 tractors assembly goes to overcoming friction between the
have been built using metric hardware. parts. The other 10% is used to tension (stretch) the
bolt. After assembly, the frictional forces disappear,
which is the basis for the saying “If it does not fail
NOTE: Be sure to use the hardware specified when
during assembly, it will not fail in service.” The bolt
using tapped holes, as trying to install a metric bolt in
may later fail due to other factors, but not from being
an inch thread, or an inch bolt in a metric thread, will
over tightened.
damage the thread.
Certain hardware must be tightened to specific LOCKNUTS

torque specifications. If specific torque specifications Most locknuts are coated with a special lubricant that
are not noted, tighten the hardware to the standard is dry to the touch. Anytime a locknut is used, a lower
torque chart specification listed in this manual. than normal torque is required. Refer to the torque
charts in this manual for specific values.
PLATING
Hardware used on Case IH tractors is plated with zinc JAM NUTS
chromate (gold color). Gold colored hardware has When using a jam nut to lock a regular nut, the jam
different torquing requirements from unplated or zinc nut should be installed first and tightened to one half
plated (silver color) hardware because of the the recommended torque, then held in place while
difference in the coefficient of friction of the plating installing a regular nut to the recommended torque.
material. The torque charts in this manual list the
correct specifications for gold, silver, and unplated
bolts. THREAD LUBRICATION
The addition of antiseize compound, Molykote, oil,
NUT TIGHTENING graphite, or any other lubricant to a bolt decreases
the friction between it and a nut. This makes it
Whenever possible, the nut should be tightened, not necessary to reduce the recommended torque to
the head of the bolt. When tightening using the bolt prevent over tensioning of the bolt. When using the
head, the clamp load can be lost because some of torque charts in this manual, decrease the value by
the torque applied twists the bolt instead of 20% whenever a lubricant is used.
tensioning (stretching) it. The tension on the bolt is
what holds the joint together.
00-4
SAFETY PRECAUTIONS
A careful operator is the best operator. Most satisfactory condition to ensure your safety and
accidents can be avoided by observing certain comply with legal requirements.
precautions. To help prevent accidents, read and
4. Keep open flame or cold weather starting aids
take the following precautions before operating this
away from the battery to prevent fires or
tractor. Equipment should be operated only by those
explosions. Use jumper cables according to
who are responsible and instructed to do so.
instructions to prevent sparks which could cause
explosion.
THE TRACTOR
5. Stop the engine before performing any service
1. Read the Operator’s Manual carefully before on the tractor.
using the tractor. Lack of operating knowledge
6. Escaping hydraulic/diesel fluid under pressure
can lead to accidents.
can penetrate the skin causing serious injury. If
2. Use an approved roll bar and seat belt for safe fluid is injected into the skin, obtain medical
operation. Overturning a tractor without a roll bar attention immediately or gangrene may result.
can result in death or injury. If your tractor is not
• DO NOT use your hand to check for leaks.
equipped with a roll bar and seat belt, see your
Use a piece of cardboard or paper to search
Case IH Dealer.
for leaks.
3. Always use the seat belt. The only instance when • Stop the engine and relieve pressure before
the seat belt should not be used is if the roll bar connecting or disconnecting lines.
has been removed from the tractor or folding
• Tighten all connections before starting the
ROPS is in down position.
engine or pressurizing lines.
4. If a front end loader is to be installed, always use 7. Do not modify or permit anyone else to modify or
a FOPS (Falling Object Protective Structure) alter this tractor or any of its components or
canopy to avoid injury from falling objects. functions without first consulting a Case IH
5. Use the handholds and step plates when getting Dealer.
on and off the tractor to prevent falls. Keep steps 8. The fuel oil in the injection system is under high
and platform cleared of mud and debris. pressure and can penetrate the skin. Unqualified
6. Do not permit anyone but the operator to ride on persons should not remove or attempt to adjust
the tractor. There is no safe place for extra riders. a pump, injector, nozzle, or any other part of the
fuel injection system. Failure to follow these
7. Keep all safety decals clean of dirt and grime, instructions can result in serious injury.
and replace all missing, illegible, or damaged
safety decals. See the list of decals in the Decal 9. Continuous long-term contact with used engine
section of this manual. oil may cause skin cancer. Avoid prolonged
contact with used engine oil. Wash skin promptly
SERVICING THE TRACTOR with soap and water.
1. The cooling system operates under pressure 10. Some components of your tractor, such as
which is controlled by the radiator cap. It is gaskets and friction surfaces (brake linings,
dangerous to remove the cap while the system is clutch linings, etc.) may contain asbestos.
hot. Always turn the cap slowly to the first stop Breathing asbestos dust is dangerous to your
and allow pressure to escape before removing health. You are advised to have any mainte-
the cap entirely. nance or repair on such components carried out
by an authorized Case IH Dealer. However, if
2. Keep any type of open flame away from the
service operations are to be undertaken on parts
tractor and do not smoke while refueling. Wait for
that contain asbestos, the essential precautions
the engine to cool before refueling.
listed below must be observed:
3. Keep the tractor and equipment, particularly
brakes and steering, maintained in a reliable and
00-5
• Work out of doors or in a well ventilated area. 11. Always set the hydraulic selector lever in position
• Dust found on the tractor or produced during control when attaching or transporting equip-
work on the tractor should be removed by ment. Ensure hydraulic couplers are properly
extraction, not by blowing. mounted and will disconnect safely in case of
accidental detachment of implement.
• Dust waste should be dampened, placed in
a sealed container, and marked to ensure 12. Do not leave equipment in the raised position.
safe disposal.
13. Use the flasher/turn signal lights and SMV signs
• If any cutting, drilling, etc. is attempted on when traveling on public roads both day and
materials containing asbestos, the item night (unless prohibited by law).
should be dampened and only hand tools or
low speed power tools used. 14. When operating at night, adjust lights to prevent
blinding oncoming drivers.
OPERATING THE TRACTOR
DRIVING THE TRACTOR
1. Before starting the tractor, apply the parking
brake, place the PTO lever in the “OFF” position, 1. Watch where you are going, especially at row
the lift control lever in the down position, the ends, on roads, around trees and low hanging
remote control valve levers in the neutral obstacles.
position, and the transmission in neutral.
2. To avoid upsets, drive the tractor with care and at
2. Always sit in the tractor seat when starting the a safe speed. Use extra caution when operating
engine or operating controls. Do not start the over rough ground, when crossing ditches or
engine or operate controls while standing beside slopes, and when turning corners.
the tractor.
3. To provide two-wheel braking, lock tractor brake
3. Do not bypass the neutral start switches. Consult pedals together when transporting on roads.
your Case IH Dealer if your neutral start controls
4. Do not coast or free wheel down hills. Use the
malfunction. Use jumper cables only in the
same gear when going downhill as is used when
recommended manner. Improper use can result
going uphill.
in tractor runaway.
5. Any towed vehicle with a total weight exceeding
4. Avoid accidental contact with the gear shift lever
that of the towing tractor should be equipped with
while the engine is running, as this can cause
brakes for safe operation.
unexpected tractor movement.
6. If the tractor becomes stuck or the tires become
5. Before getting off the tractor, disengage the PTO,
frozen to the ground, back up the tractor to
turn the engine off, and apply the parking brake.
prevent upset.
Never get off the tractor while it is in motion.
7. Always check overhead clearance, especially
6. Do not park the tractor on a steep incline.
when transporting the tractor.
7. Do not operate the tractor engine in an enclosed
8. When operating at night, adjust lights to prevent
building without adequate ventilation. Exhaust
blinding oncoming drivers.
fumes can cause death or illness.
8. If the power steering or engine ceases operating, OPERATING THE PTO
stop the tractor immediately. 1. When operating PTO driven equipment, shut off
9. Pull only from the drawbar or the lower link the engine and wait until the PTO stops before
drawbar in the down position. Use only a drawbar getting off the tractor and disconnecting the
pin that locks in place. Pulling from the tractor equipment.
rear axle or any point above the axle may cause 2. Do not wear loose clothing when operating the
the tractor to upset. power take-off or when near rotating equipment.
10. 1If the front end of the tractor tends to rise when 3. When operating stationary PTO driven equip-
heavy implements are attached to the three- ment, always place all gear shift levers in neutral
point hitch, install front end or front wheel position.
weights. Do not operate the tractor with a light
front end. Apply the tractor parking brake, and block the
rear wheels front and back.
00-6
4. To avoid injury, do not clean, adjust, unclog, or 9. Keep equipment clean and properly maintained.
service PTO driven equipment when the tractor
10. Do not drive equipment near open fires.
engine is running.
11. Never use fuel for cleaning purposes.
5. Ensure the PTO master shield is installed at all
times. Always replace the PTO shield cap when 12. Arrange fuel purchases so that winter grade fuels
the PTO is not in use. are not held over and used in the spring.
DIESEL FUEL SAFETY FRAME (ROPS)

1. UNDER NO CIRCUMSTANCES should gaso- Your Case IH tractor is equipped with a safety frame.
line, alcohol, or blended fuels be added to diesel It must be maintained in a serviceable condition. Be
fuel. These combinations can create an careful when driving through doorways or working in
increased fire or explosive hazard. Such blends confined spaces with low headroom.
are more explosive than pure gasoline in a
closed container such as a fuel tank. DO NOT UNDER NO CIRCUMSTANCES should you:
USE THESE BLENDS.
• modify, drill, or alter the safety frame in any way.
2. Never remove the fuel cap or refuel with the Doing so may render you liable to legal
engine running or hot. prosecution.
3. Do not smoke while refueling or when standing • attempt to straighten or weld any part of the main
near fuel. frame or retaining brackets which have suffered
damage. Doing so may weaken the structure and
4. Maintain control of the fuel filler pipe nozzle when
endanger your safety.
filling the tank.
• secure any parts on the main frame or attach
5. Do not fill the fuel tank to capacity. Allow room for your safety frame with anything other than the
expansion. special high tensile bolts and nuts specified.
6. Wipe up spilled fuel immediately. • attach chains or ropes to the main frame for
pulling purposes.
7. Always tighten the fuel tank cap securely.
• take unnecessary risks even though your safety
8. If the original fuel tank cap is lost, replace it with frame affords you the maximum protection
a Case IH approved cap. A non-approved, possible.
proprietary cap may not be safe.
WHEN YOU SEE THIS SYMBOL

IT MEANS:
ATTENTION!
BECOME ALERT!
YOUR SAFETY IS INVOLVED!
00-7
DECALS - D35, D40, D45

If safety or instruction decals become damaged or illegible, new decals should be obtained from your Case IH
Dealer and placed at their original positions.
SAFETY DECALS
WARNING
WARNING
WARNING: Pull Only From Drawbar

PART NO: 86532904
LOCATION: PTO Shield
WARNING
WARNING: Rotating Fan

and Belts
PART NO: 86532907
LOCATION: Both Sides
of Radiator
WARNING: Start Engine

WARNING
Only From
Operator’s Seat
PART NO: 86579295
LOCATION: On the Starter Motor
WARNING
WARNING: To Jump Start

PART NO: 86402367
LOCATION: Front of Coolant
Overflow Tank
DANGER: ROPS WARNING: Before Starting

PART NO: 86401130 and Operating
LOCATION: Top under side of ROPS PART NO: 86401125
LOCATION: Left Console Panel
00-8
INSTRUCTION DECALS - D35, D40, D45
Front-Wheel Drive
Control Lever
PART NO: 86400177
Operating Remote Control
LOCATION: Left Fender
Valve-Single Spool
PART NO: 86567895
LOCATION: Right-Hand
Fender
Position Control Lever

PART NO: 86571897
LOCATION: Right-Hand
Quadrant
PTO Engagement
PART NO: 86567890
LOCATION: Left-Hand
Seat Pan
Range Selector Lever

(Manual)
PART NO: 86567891
LOCATION: Left fender
00-9
Hyd. Manifold Operation

(See Operator’s Manual) Engine Oil
PART NO: 86532914 Starter Switch PART NO: 86532916
LOCATION: Right-Hand Side PART NO: 86400175 LOCATION: Engine Oil
of Hyd. Manifold/Air Filter Cap LOCATION: Starter Switch, Filler Cap
Right Side of Instrument Panel
Coupler--Extending Coupler--Retracting
PART NO: 86532920 PART NO: 86532919
Main Shift Lever
PART NO: 86567892
LOCATION: Top right of dash
Forward-Reverse Shuttle
PART NO: 86532921 PART NO: 86532922
PART NO: 86567887
LOCATION: Top Left
of Dash
Power Steering Fluid

PART NO: 86532903
LOCATION: Top of P.S.
Reservoir
Operating Remote
Control Valve--
Double Spool Lubrication and
PART NO: 86532911 Maintenance Intervals
LOCATION: Cover of PART NO: 86400357
2-Spool Remote Valve LOCATION: Inside of Hood
00-10
Flow Control Valve

PART NO: 86400295
Parking Brake
LOCATION: Differential Lock
PART NO: 86521672
Top of Flow Control Knob PART NO: 86532901
LOCATION: Right Front
LOCATION: Right Rear
Deck Platform
Deck Platform
Air Cleaner Maintenance

PART NO: 86401636
LOCATION: Air Cleaner Canister
Turn Signal Red Reflective Tape

PART NO: 86400176 PART NO: 86400366
LOCATION: Top Left Dash LOCATION: Back Rear Fender
Throttle ROPS Certification

PART NO: FONN9N848BA LOCATION: Inner Right Upright
LOCATION: Top Right Dash
00-11
DECALS - DX35, DX40, DX45

If safety or instruction decals become damaged or illegible, new decals should be obtained from your Case IH
Dealer and placed at their original positions.
SAFETY DECALS
WARNING WARNING
WARNING
WARNING: Pull Only From Drawbar

PART NO: 86532904
LOCATION: PTO Shield
WARNING
WARNING: Rotating Fan

WARNING: To Jump Start and Belts
PART NO: 86402367 PART NO: 86532907
LOCATION: Coolant overflow tank LOCATION: Both sides of
Radiator Shroud
WARNING: Before Starting

and Operating
PART NO: 86401125
LOCATION: Inside Left-Hand Fender
DANGER: ROPS
PART NO: 86543805
LOCATION: Top under side of ROPS
WARNING
WARNING: Start Engine Only

From
Operator’s Seat
PART NO: 86579295
LOCATION: On Starter Motor
WARNING: Lock Park Brake
PART NO: 86576391
LOCATION: Right Side Dash
Left of handle throttle
00-12
INSTRUCTION DECALS - DX35, DX40, DX45

Range Selector Position Control Operating Remote
Lever Lever Control
(Hydrostatic)
PART NO: PART NO: Valve-Single
86567894 86567896 Spool
LOCATION: LOCATION: PART NO:
Left-Hand POD Top Right-Hand POD Top 86567895
LOCATION:
Right-Hand POD Top
PTO Engagement
PART NO: 86567890
LOCATION: Left-Hand
Pod Top
Front-Wheel PTO Control PTO Control

Drive Control Lever (Rear) Lever (Mid)
Lever PART NO: PART NO:
PART NO: 86400314 86400315
86400177 LOCATION: LOCATION:
LOCATION: Left-Hand POD Top Left-Hand POD Top
Left-Hand POD Top
00-13
Differential Lock Starter Switch Flow Control Valve Engine Oil

PART NO: PART NO: PART NO: PART NO:
86532901 86400175 86400295 86532916
LOCATION:Above LOCATION: LOCATION: LOCATION:
Pedal Left Side of Starter Switch, Top of Flow Control Engine Oil Filler Cap
Operator’s Platform Right Side of Knob
Instrument Panel
PART NO:86532920 PART NO:86532919
Hyd. Manifold Operation
(See Operator’s Manual)
PART NO:
86532914
LOCATION:
Right-Hand Side of Hyd.
Manifold/Air Filter Cap Coupler--Extending Coupler--Retracting
PART NO:86532921 PART NO:86532922
Power Steering Fluid

PART NO:
86532903
LOCATION:
Operating Remote Top of P.S. Reservoir
Control Valve--
Double Spool
PART NO:
86532911
LOCATION:
Cover of 2-Spool Lubrication and
Remote Valve Maintenance Intervals
PART NO:
86400357
LOCATION:
Inside of Hood
00-14
Parking Brake
PART NO: 86521672
LOCATION: Left Side Air Cleaner Maintenance
Seat Platform PART NO: 86401636
LOCATION: Air Cleaner Canister
Turn Signal Red Reflective Tape

PART NO: 86400176 PART NO: 86400366
LOCATION: Top Left Dash LOCATION: Back Rear Fender
ROPS Certification
LOCATION: Inner Right Upright
Throttle
PART NO: FONN9N848BA
LOCATION: Top Right Dash
00-15
PLEASE READ CAREFULLY: CNH America LLC is continually striving to improve

For a complete list of the pre-delivery service checks its products. We reserve the right to change prices,
performed by your dealer, refer to the specification, or equipment at any time without
PRE-DELIVERY SERVICE checklist found at the notice.
back of this section.
All data given in this book is subject to production
A PRODUCT IDENTIFICATION PLATE is located on variations. Dimensions and weights are approximate
the left-hand side of the transmission housing. The only, and the illustrations do not necessarily depict
numbers on the plate are important in the event your tractors in standard condition. For exact information
tractor should require future service. For your about any particular tractor, please consult your
convenience, have your dealer record these Case IH dealer.
numbers in the appropriate spaces below.
00-16
INTERNATIONAL SYMBOLS
As a guide to the operation of your tractor, various international symbols have been used on instruments and
controls. These symbols are depicted and described below.
Engine Speed Low Range Battery
Hours Recorded Neutral Power Take-off

(ON)
Engine Water Diesel Fuel Power Take-off

Temperature (OFF)
Air Filter Glow “Tortoise” - SLOW

or Minimum Setting
Engine Oil
Engine Stop
Pressure “Hare” - FAST
or Maximum Setting
Engine Oil
Hazard Warning Warning
Parking Brake
Axle Connect
Control Lever
Operating Direction
Lights
Axle Disconnect
(Upper Beam)
Lift Arms
(Raised)
Lights
Continuously (Lower Beam)
Variable Lift Arms
(Lowered)
Lock
Increase Remote Cylinder
(Float)
Release Lock Remote Cylinder

Decrease
(Retracted)
Up Remote Cylinder
(Extended)
Fuel Level
Down
Forward
High Range Differential Lock Warning!

Contains Asbestos
Read Operator’s
Middle Range Manual
00-17
SPECIFICATIONS - D35, D40, D45
Model D35 Model D40 Model D45

ENGINE
Type/Model . . . . . . . . . . . . . . . Diesel/N843L Diesel/N844 Diesel/N844L
Engine Gross Horsepower . . 26.1 kw (35.0) 29.8 kw (40.0) 33.6 kw (45)
Cylinders . . . . . . . . . . . . . . . . . 3 4 4
Bore . . . . . . . . . . . . . . . . . . . . . 84 mm (3.31″) 84 mm (3.31″) 84 mm (3.31″)
Stroke . . . . . . . . . . . . . . . . . . . 100 mm (3.94″) 90 mm (3.54″) 100 mm (3.94″)
Displacement . . . . . . . . . . . . . 1.65 L 2.0 L 2.2 L
(101.1 cu. in.) (121.7 cu. in.) (135.2 cu. in.)
Compression Ratio . . . . . . . . 22.5:1 22.5:1 22.5:1
Firing Order . . . . . . . . . . . . . . 1-2-3 1-3-4-2 1-3-4-2
Low Idle Speed . . . . . . . . . . . 1025 ± 50 rpm 1025 ± 50 rpm 1025 ± 50 rpm
Maximum Speed:
High Idle . . . . . . . . . . . . . . . . 2855 rpm 2855 rpm 2855 rpm
Rated . . . . . . . . . . . . . . . . . . 2600 rpm 2600 rpm 2600 rpm
CAPACITIES
Fuel Tank . . . . . . . . . . . . . . . . 54.5 liters/ 54.5 liters/ 54.5 liters/
13 U.S. gals. 13 U.S. gals. 13 U.S. gals.
Cooling System . . . . . . . . . . . 7.4 liters/ 7.9 liters/ 8.0 liters/

7.8 U.S. qts. 8.3 U.S. qts. 8.4 U.S. qts.
Engine Crankcase:
With Filter . . . . . . . . . . . . . . . 5.8 liters/ 6.0 liters/ 6.0 liters/
Rear Axle & Transmission

(Includes Hydraulics) . . . . . . . 36 liters/ 36 liters/ 36 liters/
9.2 U.S. gals. 9.2 U.S. gals. 9.2 U.S. gals.
Power Steering . . . . . . . . . . . . 1.4 liters/ 1.4 liters/ 1.4 liters/

Front Axle Final Reduction . . . 5.3 liters/ 5.3 liters/ 5.3 liters/
/Differential Gear Case 5.6 U.S. qts. 5.6 U.S. qts. 5.6 U.S. qts.
00-18
Model D35— Model D40— Model D45—

COOLING SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . Pressurized Liquid with Pressurized Liquid with Pressurized Liquid with
Recirculating Bypass Recirculating Bypass Recirculating Bypass
Water Pump:
Type . . . . . . . . . . . . . . . . . . . Centrifugal Centrifugal Centrifugal
Drive . . . . . . . . . . . . . . . . . . . V-Belt V-Belt V-Belt
Belt
Deflection . . . . . . . . . . . . . . . 10 mm-15 mm 10 mm-15 mm 10 mm-15 mm
(7/16″-9/16″) when (7/16″-9/16″) when (7/16″-9/16″) when
9-11 kg (20-25 lbs.) 9-11 kg (20-25 lbs.) 9-11 kg (20-25 lbs.)
thumb pressure is thumb pressure is thumb pressure is
applied midway applied midway applied midway
between belt pulleys between belt pulleys between belt pulleys
Fan Diameter . . . . . . . . . . . . 410 mm (16.1″) 410 mm (16.1″) 410 mm (16.1″)
Number of Fan Blades . . . . 6 6 6
Thermostat:
Start to Open . . . . . . . . . . . . 71°C (160°F) 71°C (160°F) 71°C (160°F)
Fully Open . . . . . . . . . . . . . . 85°C (185°F) 85°C (185°F) 85°C (185°F)
Radiator Cap . . . . . . . . . . . . . 0.9 bar 0.9 bar 0.9 bar
(13 psi) (13 psi) (13 psi)
ELECTRICAL SYSTEM
Main System Protection . . . . 40 amp Maxifuse 40 amp Maxifuse 40 amp Maxifuse
Number Fuses for Circuit
Protection . . . . . . . . . . . . . . . . 7 7 7
Alternator . . . . . . . . . . . . . . . . 12-volt, Heavy Duty, 12-volt, Heavy Duty, 12-volt, Heavy Duty,
40 amps 40 amps 40 amps
Battery Type . . . . . . . . . . . . . . 12-volt, w/ negative 12-volt, w/ negative 12-volt, w/ negative
ground, 600 cca ground, 600 cca ground, 600 cca
Starter KW (hp) Rating 2.0 (2.7) 2.0 (2.7) 2.0 (2.7)
Battery Rating Amp Hrs. . . . . 64 -- 69 64 -- 69 64 -- 69
Starting Motor . . . . . . . . . . . . . Solenoid Solenoid Solenoid
Pre-Engaged Pre-Engaged Pre-Engaged
Reduction Reduction Reduction
FUEL SYSTEM
Fuel Type . . . . . . . . . . . . . . . . Diesel Diesel Diesel
Type of Fuel to Use if
Above 40°F . . . . . . . . . . . . . No. 2-Diesel, No. 2-Diesel, No. 2-Diesel,
Cetane Rating: Cetane Rating: Cetane Rating:
Minimum 40 Minimum 40 Minimum 40
Below 40°F . . . . . . . . . . . . . No. 1-Diesel, No. 1-Diesel, No. 1-Diesel,
Injection Pump:
Type . . . . . . . . . . . . . . . . . . . In-Line In-Line In-Line
Timing . . . . . . . . . . . . . . . . . . 18° BTDC 20° BTDC 18° BTDC
00-19

CLUTCH
Type . . . . . . . . . . . . . . . . . . . . . 240 mm (9.45″) 240 mm (9.45″) 260 mm (10.24″)
Dry Disc, Organic Dry Disc, Organic Dry Disc, Organic
Face Face Face
Pedal Free-Travel . . . . . . . . . 19 mm-30 mm 19 mm-30 mm 19 mm-30 mm
(3/4″-1-3/16″) (3/4″-1-3/16″) (3/4″-1-3/16″)
BRAKES
Type . . . . . . . . . . . . . . . . . . . . . Wet Disc Wet Disc Wet Disc
Disc (3 per side) . . . . . . . . . . . Out x In Out x In Out x In
175 mm x 143 mm Dia. 175 mm x 143 mm Dia. 175 mm x 143 mm Dia.
(6.9″ x 5.6″) (6.9″ x 5.6″) (6.9″ x 5.6″)
STEERING
Type . . . . . . . . . . . . . . . . . . . . . Power Power Power
Pump Flow @ Rated rpm . . . 19.4 lpm (5.13 gpm) 19.4 lpm (5.13 gpm) 19.4 lpm (5.13 gpm)
Pump Pressure Bar (psi) . . . 97.9 (1419) 97.9 (1419) 97.9 (1419)
Turns Lock-to-Lock:
2WD . . . . . . . . . . . . . . . . . . . 3.1/3.8 3.1/3.8 3.1/3.8
FWD . . . . . . . . . . . . . . . . . . . 3.1/3.8 3.1/3.8 3.1/3.8
Front Wheel Toe-In . . . . . . . . 0 mm -- 5 mm 0 mm -- 5 mm 0 mm -- 5 mm
(0″ -- 13/64″) (0″ -- 13/64″) (0″ -- 13/64″)
Turning Radius w/o Brakes:
2WD . . . . . . . . . . . . . . . . . . . 2819 mm (111″) 2819 mm (111″) 2819 mm (111″)
FWD . . . . . . . . . . . . . . . . . . . 3099 mm (122″) 3099 mm (122″) 3099 mm (122″)
Max. Turn Angle:
2WD 59° 59° 59°
FWD 54° 54° 54°
Front to rear axle ratio . . . . . . 1.660 to 1 1.660 to 1 1.660 to 1
POWER TAKE-OFF
Type . . . . . . . . . . . . . . . . . . . . . Independent Independent Independent
Type Actuation . . . . . . . . . . . . Manual lever to Manual lever to Manual lever to
hydraulic valve hydraulic valve hydraulic valve
Shaft:
Rear PTO . . . . . . . . . . . . . . . 35 mm (1-3/8″) 35 mm (1-3/8″) 35 mm (1-3/8″)
Engine Speed for 540 rpm
Rear PTO Operation . . . . . . . 2400 rpm 2400 rpm 2400 rpm
Horsepower PTO Observed . 22.0 kw (29.6 hp) 26.1 kw (35.0 hp) 29.5 kw (39.6 hp)
HYDRAULIC LIFT SYSTEM

Type . . . . . . . . . . . . . . . . . . . . . Open Center Open Center Open Center
Pump Type . . . . . . . . . . . . . . . Gear Gear Gear
Pump Capacity . . . . . . . . . . . . 9.8. lpm 9.8 lpm 9.8 lpm
(37.1 U.S. gpm) (37.1 U.S. gpm) (37.1 U.S. gpm)
System Relief Valve Setting . 160 bar (2275 psi) 170 bar (2500 psi) 170 bar (2500 psi)
Number of Rear Remotes . . . 2 (optional) 2 (optional) 2 (optional)
Number of Front Remotes . . 2 (optional) 2 (optional) 2 (optional)
00-20
TRANSMISSION
Transmission Type . . . . . . . . 12 x 12 gear 12 x 12 gear 12 x 12 gear
Shuttle Shift Type . . . . . . . . . . Synchronized Synchronized Synchronized
Traction Clutch Type . . . . . . . Dry disc Dry disc Dry disc
Number of Plates & Lining

Type . . . . . . . . . . . . . . . . . . . . . 1 (organic) 1 (organic) 1 (organic)
Clutch Diameter mm (in.) . . . 240 (9.45) 240 (9.45) 260 (10.24)
Transmission Speeds - Forward
(2,600 rpm Engine (2,600 rpm Engine (2,600 rpm Engine

Main Range speed with 13.6 x 24 speed with 13.6 x 24 speed with 13.6 x 24
Gear Gear rear tires) rear tires) rear tires)
1st Low . . . . . . . . . . 1.53 kph 1.53 kph 1.53 kph

(0.95 mph) (0.95 mph) (0.95 mph)
2nd . . . . . . . . . . . . . . . . . . . . . 1.94 kph 1.94 kph 1.94 kph

(1.21 mph) (1.21 mph) (1.21 mph)
3rd . . . . . . . . . . . . . . . . . . . . . 2.43 kph 2.43 kph 2.43 kph

(1.51 mph) (1.51 mph) (1.51 mph)
4th . . . . . . . . . . . . . . . . . . . . . 3.21 kph 3.21 kph 3.21 kph

(1.99 mph) (1.99 mph) (1.99 mph)
1st Medium . . . . . . . 4.14 kph 4.14 kph 4.14 kph

(2.57 mph) (2.57 mph) (2.57 mph)
2nd . . . . . . . . . . . . . . . . . . . . . 5.28 kph 5.28 kph 5.28 kph

(3.28 mph) (3.28 mph) (3.28 mph)
3rd . . . . . . . . . . . . . . . . . . . . . 6.59 kph 6.59 kph 6.59 kph

(4.10 mph) (4.10 mph) (4.10 mph)
4th . . . . . . . . . . . . . . . . . . . . . 8.71 kph 8.71 kph 8.71 kph

(5.41 mph) (5.41 mph) (5.41 mph)
1st High . . . . . . . . . . 10.80 kph 10.80 kph 10.80 kph

(6.69 mph) (6.69 mph) (6.69 mph)
2nd . . . . . . . . . . . . . . . . . . . . . 13.72 kph 13.72 kph 13.72 kph

(8.52 mph) (8.52 mph) (8.52 mph)
3rd . . . . . . . . . . . . . . . . . . . . . 17.14 kph 17.14 kph 17.14 kph

(10.65 mph) (10.65 mph) (10.65 mph)
4th . . . . . . . . . . . . . . . . . . . . . 22.64 kph 22.64 kph 22.64 kph

(14.07 mph) (14.07 mph) (14.07 mph)
00-21
Transmission Speeds - Reverse
(2,600 rpm Engine (2,600 rpm Engine (2,600 rpm Engine

Main Range Speed with 13.6 x 24 Speed with 13.6 x 24 Speed with 13.6 x 24
Gear Gear Rear Tires) Rear Tires) Rear Tires)
1st Low . . . . . . . . . . 1.71 kph 1.71 kph 1.71 kph

(1.06 mph) 1.06 mph) 1.06 mph)
2nd . . . . . . . . . . . . . . . . . . . . . 2.18 kph 2.18 kph 2.18 kph

(1.35 mph) (1.35 mph) (1.35 mph)
3rd . . . . . . . . . . . . . . . . . . . . . 2.72 kph 2.72 kph 2.72 kph

(1.69 mph) (1.69 mph) (1.69 mph)
4th . . . . . . . . . . . . . . . . . . . . . 3.60 kph 3.60 kph 3.60 kph

(2.23 mph) (2.23 mph) (2.23 mph)
1st Medium . . . . . . . 4.64 kph 4.64 kph 4.64 kph

(2.88 mph) (2.88 mph) (2.88 mph)
2nd . . . . . . . . . . . . . . . . . . . . . 5.91 kph 5.91 kph 5.91 kph

(3.68 mph) (3.68 mph) (3.68 mph)
3rd . . . . . . . . . . . . . . . . . . . . . 7.39 kph 7.39 kph 7.39 kph

(4.59 mph) (4.59 mph) (4.59 mph)
4th . . . . . . . . . . . . . . . . . . . . . 9.76 kph 9.76 kph 9.76 kph

(6.06 mph) (6.06 mph) (6.06 mph)
1st High . . . . . . . . . . 12.10 kph 12.10 kph 12.10 kph

(7.50 mph) (7.50 mph) (7.50 mph)
2nd . . . . . . . . . . . . . . . . . . . . . 15.40 kph 15.40 kph 15.40 kph

(9.56 mph) (9.56 mph) (9.56 mph)
3rd . . . . . . . . . . . . . . . . . . . . . 19.21 kph 19.21 kph 19.21 kph

(11.94 mph) (11.94 mph) (11.94 mph)
4th . . . . . . . . . . . . . . . . . . . . . 25.38 kph 25.38 kph 25.38 kph

(15.77 mph) (15.77 mph) (15.77 mph)
00-22
CAST IRON WEIGHTS

Front End:
Ag, R-4 & Turf Tires with
FWD . . . . . . . . . . . . . . . . . . . (2) weights @ 29.7 kg (2) weights @ 29.7 kg (2) weights @ 29.7 kg
(66 lbs.) each (66 lbs.) each (66 lbs.) each
Optional (2) weights @ Optional (2) weights @ Optional (2) weights @

45 kg (100 lbs.) each 45 kg (100 lbs.) each 45 kg (100 lbs.) each
Rear Wheel:
R-4 Tires . . . . . . . . . . . . . . . . (4) weights (2) per (4) weights (2) per (4) weights (2) per
wheel @ 48 kg wheel @ 48 kg wheel @ 48 kg
Turf Tires . . . . . . . . . . . . . . . --- --- ---
Ag. Tires . . . . . . . . . . . . . . . . (4) weights (2) per (4) weights (2) per (4) weights (2) per
DRAWBARS
Swinging/
Extendible . . . . . . . . . . . . . . . . Standard Standard Standard
3 POINT HITCH
Category Type . . . . . . . . . . . . I I I
Position Control Type . . . . . . Hydraulic Hydraulic Hydraulic
Draft Control Type . . . . . . . . . Top Link Sensing (DIA) Top Link Sensing (DIA) Top Link Sensing (DIA)
Drop Rate Control . . . . . . . . . Standard Standard Standard
Lift Capacity @ 24″
Behind kg (lbs.) . . . . . . . . . . . 920 (2025) 1059 (2330) 1059 (2330)
TIRES
FRONT:
Agricultural:
2WD . . . . . . . . . . . . . . . . . . . 5.50 x 16, 4PR, F2 5.50 x 16, 4PR, F2 5.50 x 16, 4PR, F2
7.50 x 15, 6PR, F2 7.50 x 15, 6PR, F2 7.50 x 15, 6PR, F2
FWD . . . . . . . . . . . . . . . . . . . 7 x 16, 6PR, R1 7 x 16, 6PR, R1 7 x 16, 6PR, R1

8 x 16, 6 PR, R1 8 x 16, 6 PR, R1 8 x 16, 6 PR, R1
Turf:
2WD . . . . . . . . . . . . . . . . . . . 25 x 8.50-14, 4PR, R3 25 x 8.50-14, 4PR, R3 25 x 8.50-14, 4PR, R3
FWD . . . . . . . . . . . . . . . . . . . 27 x 8.50-15, 4PR, R3 27 x 8.50-15, 4PR, R3 27 x 8.50-15, 4PR, R3
Industrial:
FWD . . . . . . . . . . . . . . . . . . . 10 x 16.50, 6PR, R4 10 x 16.50, 6PR, R4 10 x 16.50, 6PR, R4
REAR:
Agricultural . . . . . . . . . . . . . . . 13.6 x 24, 4PR, R1 13.6 x 24, 4PR, R1 13.6 x 24, 4PR, R1
14.9 x 24, 4PR, R1 14.9 x 24, 4PR, R1 14.9 x 24, 4PR, R1
Turf . . . . . . . . . . . . . . . . . . . . . . 44 x 18-20, 4PR, R3 44 x 18-20, 4PR, R3 44 x 18-20, 4PR, R3
Industrial . . . . . . . . . . . . . . . . . 17.5 x 24, 8PR, R4 17.5 x 24, 8PR, R4 17.5 x 24, 8PR, R4
00-23

WHEEL BOLT TORQUES
Front Wheel—
Disc-to-Hub:
2WD . . . . . . . . . . . . . . . . . . . 169 N⋅m 169 N⋅m 169 N⋅m
(125 ft. lbs.) (125 ft. lbs.) (125 ft. lbs.)
FWD . . . . . . . . . . . . . . . . . . . 169 N⋅m 169 N⋅m 169 N⋅m
Rear Wheel & Disc-to Axle . . 169 N⋅m 169 N⋅m 169 N⋅m
Disc-to Rim . . . . . . . . . . . . . . . 244 N⋅m 244 N⋅m 244 N⋅m

ROPS ATTACHING BOLT TORQUES

ROPS to Rear
Axle . . . . . . . . . . . . . . . . . . . . . 74 N⋅m 74 N⋅m 74 N⋅m
Seat Belt . . . . . . . . . . . . . . . . . 47.4 N⋅m 47.4 N⋅m 47.4 N⋅m
00-24
GENERAL DIMENSIONS

(1)—LENGTH Overall (Less 3 pt hitch) -- mm (in.)
2WD
sm AG Tires . . . . . . . . . . . . . 2955 (116.3) 2955 (116.3) 2955 (116.3)
lg AG Tires . . . . . . . . . . . . . . 2971 (117) 2971 (117) 2971 (117)
R4 Tires . . . . . . . . . . . . . . . . N/A N/A N/A
TURF Tires . . . . . . . . . . . . . 2892 (113.9) 2892 (113.9) 2892 (113.9)
STD FWD
sm AG Tires . . . . . . . . . . . . . 2955 (116.3) 2955 (116.3) 2955 (116.3)
lg AG Tires . . . . . . . . . . . . . . 2971 (117) 2971 (117) 2971 (117)
R4 Tires . . . . . . . . . . . . . . . . 2960 (116.5) 2960 (116.5) 2960 (116.5)
TURF Tires . . . . . . . . . . . . . 2892 (113.9) 2892 (113.9) 2892 (113.9)
(1)—LENGTH Overall (3 pt hitch horizontal position) -- mm (in.)

2WD
sm AG Tires . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 3180 (125.2)
lg AG Tires . . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 3180 (125.2)
R4 Tires . . . . . . . . . . . . . . . . N/A N/A N/A
TURF Tires . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 3180 (125.2)
STD FWD
sm AG Tires . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 3180 (125.2)
lg AG Tires . . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 3180 (125.2)
R4 Tires . . . . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 3180 (125.2)
TURF Tires . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 3180 (125.2)
00-25

HEIGHTS -- mm (in.):
(2) --
Wheel Base
FWD/2WD . . . . . . . . . . . . . . 1866 (73.5) 1866 (73.5) 1866 (73.5)
(3)—
ROPS Height - Rigid
sm AG Tires 2388 (94) 2388 (94) 2388 (94)
lg AG Tires . . . . . . . . . . . . . . 2400 (94.5) 2400 (94.5) 2400 (94.5)
R4 Tires . . . . . . . . . . . . . . . . 2400 (94.5) 2400 (94.5) 2400 (94.5)
TURF Tires . . . . . . . . . . . . . 2324 (91.5) 2324 (91.5) 2324 (91.5)
ROPS Height - FOLDING

sm AG Tires - Up . . . . . . . . 2400 (94.5) 2400 (94.5) 2400 (94.5)
sm AG Tires - Down . . . . . . 1956 (77) 1956 (77) 1956 (77)
lg AG Tires - Up . . . . . . . . . 2413 (95) 2413 (95) 2413 (95)
lg AG Tires - Down . . . . . . . 1969 (77.5) 1969 (77.5) 1969 (77.5)
R4 Tires - Up . . . . . . . . . . . . 2413 (95) 2413 (95) 2413 (95)
R4 Tires - Down . . . . . . . . . 1969 (77.5) 1969 (77.5) 1969 (77.5)
TURF Tires - Up . . . . . . . . . 2337 (92) 2337 (92) 2337 (92)
TURF Tires - Down . . . . . . . 1892 (74.5) 1892 (74.5) 1892 (74.5)
(4) --
Hood Height
(top inst. cluster)
sm AG TFWD . . . . . . . . . . . 1499 (59) 1499 (59) 1499 (59)
lg AG FWD . . . . . . . . . . . . . . 1511 (59.5) 1511 (59.5) 151 (59.51)
R4 FWD . . . . . . . . . . . . . . . . 1524 (60) 1524 (60) 1524 (60)
TURF FWD . . . . . . . . . . . . . 1473 (58) 1473 (58) 1473 (58)
(5) --
Steering Wheel Height
sm AG TFWD . . . . . . . . . . . 1600 (63) 1600 (63) 1600 (63)
lg AG FWD . . . . . . . . . . . . . . 1613 (63.5) 1613 (63.5) 1613 (63.5)
R4 FWD . . . . . . . . . . . . . . . . 1626 (64) 1626 (64) 1626 (64)
TURF FWD . . . . . . . . . . . . . 1575 (62) 1575 (62) 1575 (62)
00-26
D35 D40 D45

(6)—WIDTH:
Rear Axle—
Outside to Outside:
Turf Tires—
Dished In . . . . . . . . . . . . . . . 1825 mm (71.8″) 1825 mm (71.8″) 1825 mm (71.8″)
Dished Out . . . . . . . . . . . . . . 1846 mm (72.7″) 1846 mm (72.7″) 1846 mm (72.7″)
Ag. Tires— (Large)
Dished In . . . . . . . . . . . . . . . 1693 mm (66.6″) 1693 mm (66.6″) 1693 mm (66.6″)
R4 Tires—
Dished In . . . . . . . . . . . . . . . 1736 mm (68.3″) 1736 mm (68.3″) 1736 mm (68.3″)
(7)—MINIMUM GROUND CLEARANCE:

sm AG TIRES
(D.) - Minimum Centerline 13 (330) 13 (330) 13 (330)
Clearance
(E.) - Frt Axle Crop Clear. - 15.5 (394) 15.5 (394) 15.5 (394)
15″ from CL
(F.) - Rr Axle Crop Clear. - 17.5 (445) 17.5 (445) 17.5 (445)
15″ from CL
lg AG TIRES
Clearance
15″ from CL
(F.) - Rr Axle Crop Clear. - 18 (457) 18 (457) 18 (457)
15″ from CL
R4 TIRES
Clearance
15″ from CL
(F.) - Rr Axle Crop Clear. - 17.5 (444) 17.5 (444) 17.5 (444)
15″ from CL
TURF TIRES
(D.) - Minimum Centerline 11.5 (292) 11.5 (292) 11.5 (292)
Clearance
(E.) - Frt Axle Crop Clear. - 13 (330) 13 (330) 13 (330)
15″ from CL
(F.) - Rr Axle Crop Clear. - 15 (381) 15 (381) 15 (381)
15″ from CL
CL -- Center Line of Tractor
00-27
5 4
2
1
50045712
20035686
00-28

WHEEL TREAD SETTINGS:
FRONT AXLE:
Agricultural:
2WD 5.5 x 16
Position 1 . . . 1094 - 1208 mm 1094 - 1208 mm 1094 - 1208 mm
(43.1″ - 47.5″) (43.1″ - 47.5″) (43.1″ - 47.5″)
Position 2 . . . 1194 - 1308 mm 1194 - 1308 mm 1194 - 1308 mm
(47.0″ - 51.5″) (47.0″ - 51.5″) (47.0″ - 51.5″)
Position 3 . . . 1294 - 1408 mm 1294 - 1408 mm 1294 - 1408 mm
(51.0″ - 55.4″) (51.0″ - 55.4″) (51.0″ - 55.4″)
Position 4 . . . 1394 - 1508 mm 1394 - 1508 mm 1394 - 1508 mm
(54.9″ - 59.4″) (54.9″ - 59.4″) (54.9″ - 59.4″)
Position 5 . . . 1494 - 1608 mm 1494 - 1608 mm 1494 - 1608 mm
(58.8″ - 69.3″) (58.8″ - 69.3″) (58.8″ - 69.3″)
7.5 x 16
Position 1 . . . 1125 - 1172 mm 1125 - 1172 mm 1125 - 1172 mm
(44.3″ - 46.1″) (44.3″ - 46.1″) (44.3″ - 46.1″)
Position 2 . . . 1225 - 1272 mm 1225 - 1272 mm 1225 - 1272 mm
(48.2″ - 50.1″) (48.2″ - 50.1″) (48.2″ - 50.1″)
Position 3 . . . 1325 - 1372 mm 1325 - 1372 mm 1325 - 1372 mm
(52.2″ - 54.0″) (52.2″ - 54.0″) (52.2″ - 54.0″)
Position 4 . . . 1425 - 1472 mm 1425 - 1472 mm 1425 - 1472 mm
(56.1″ - 57.9″) (56.1″ - 57.9″) (56.1″ - 57.9″)
Position 5 . . . 1525 - 1572 mm 1525 - 1572 mm 1525 - 1572 mm
(60.1″ - 61.9″) (60.1″ - 61.9″) (60.1″ - 61.9″)
FWD 7 x 16 . . . . . . 1183.6 mm 1183.6 mm 1183.6 mm

(46.4″) (46.4″) (46.4″)
8 x 16 . . . . . . 1183.6 mm 1183.6 mm 1183.6 mm
(46.4″) (46.4″) (46.4″)
Turf:
2WD 25 x 8.5-14
Position 1 . . . 1144 -1164 mm 1144 -1164 mm 1144 -1164 mm
(45.1″ - 45.8″) (45.1″ - 45.8″) (45.1″ - 45.8″)
Position 2 . . . 1244 - 1264 mm 1244 - 1264 mm 1244 - 1264 mm
(49.0″ - 49.7″) (49.0″ - 49.7″) (49.0″ - 49.7″)
Position 3 . . . 1344 - 1364 mm 1344 - 1364 mm 1344 - 1364 mm
(52.9″ - 53.7″) (52.9″ - 53.7″) (52.9″ - 53.7″)
Position 4 . . . 1444 - 1464 mm 1444 - 1464 mm 1444 - 1464 mm
(56.9″ - 57.6″) (56.9″ - 57.6″) (56.9″ - 57.6″)
Position 5 . . . 1544 - 1564 mm 1544 - 1564 mm 1544 - 1564 mm
(60.8″ - 61.6″) (60.8″ - 61.6″) (60.8″ - 61.6″)
FWD 27 x 8.5-15 . . . . . . . . 1264.9 mm (49.8″) 1264.9 mm (49.8″) 1264.9 mm (49.8″)
Industrial:
FWD 10 x 16.5 . . . 1252.2 mm (49.3″) 1252.2 mm (49.3″) 1252.2 mm (49.3″)
00-29
REAR AXLE:
Agricultural:
2WD & FWD 13.6 x 24 . . . 1196.3 - 1712.0 mm 1196.3 - 1712.0 mm 1196.3 - 1712.0 mm
(47.1 - 67.4″) (47.1 - 67.4″) (47.1 - 67.4″)
14.9 x 24 . . . 1206.5 - 1712.0 mm 1206.5 - 1712.0 mm 1206.5 - 1712.0 mm
(47.5 - 67.4″) (47.5 - 67.4″) (47.5 - 67.4″)
Turf:
2WD & FWD 44 x 18-20 . . 1346.2 - 1369.1 mm 1346.2 - 1369.1 mm 1346.2 - 1369.1 mm
(53 - 53.9″) (53 - 53.9″) (53 - 53.9″)
Industrial:
FWD 17.5 x 24 . . . 1300.5 - 1712.0 mm 1300.5 - 1712.0 mm 1300.5 - 1712.0 mm
(51.2 - 67.4″) (51.2 - 67.4″) (51.2 - 67.4″)
WEIGHT (Bare Tractor):

With ROPS:
2WD . . . . . . . . . . . . . . . . . . . 1142 kg 1165 kg 1257 kg
(2513 lbs.) (2564 lbs.) (2766 lbs.)
FWD . . . . . . . . . . . . . . . . . . . 1195 kg 1218 kg 1309 kg
(2628 lbs.) (2679 lbs.) (2881 lbs.)
00-30
SPECIFICATIONS - DX35, DX40, DX45
Model DX35— Model DX40— Model DX45—

Hydrostatic Hydrostatic Hydrostatic
ENGINE
Type/Model . . . . . . . . . . . . . . . Diesel/N843L Diesel/N844 Diesel/N844L
Engine Gross Horsepower . . 26.1 kw (35.0) 29.8 kw (40.0) 33.6 kw (45)
Cylinders . . . . . . . . . . . . . . . . . 3 4 4
Bore . . . . . . . . . . . . . . . . . . . . . 84 mm (3.31″) 84 mm (3.31″) 84 mm (3.31″)
Stroke . . . . . . . . . . . . . . . . . . . 100 mm (3.94″) 90 mm (3.54″) 100 mm (3.94″)
Displacement . . . . . . . . . . . . . 1.65 L 2.0 L 2.2 L
(101.1 cu. in.) (121.7 cu. in.) (135.2 cu. in.)
Compression Ratio . . . . . . . . 22.5:1 22.5:1 22.5:1
Firing Order . . . . . . . . . . . . . . 1-2-3 1-3-4-2 1-3-4-2
Low Idle Speed . . . . . . . . . . . 1025 rpm 1025 rpm 1025 rpm
Maximum Speed:
High Idle . . . . . . . . . . . . . . . . 2855 rpm 2855 rpm 2855 rpm
Rated . . . . . . . . . . . . . . . . . . 2600 rpm 2600 rpm 2600 rpm
CAPACITIES
Fuel Tank . . . . . . . . . . . . . . . . 54.5 liters/ 54.5 liters/ 54.5 liters/
13 U.S. gals. 13 U.S. gals. 13 U.S. gals.
Cooling System . . . . . . . . . . . 7.4 liters/ 7.9 liters/ 8.0 liters/

Engine Crankcase:
With Filter . . . . . . . . . . . . . . . 5.8 liters/ 6.0 liters/ 6.0 liters/
Rear Axle & Transmission

(Includes Hydraulics) . . . . . . . 36 liters/ 36 liters/ 36 liters/
9.6 U.S. gals. 9.6 U.S. gals. 9.6 U.S. gals.
Power Steering . . . . . . . . . . . . 1.4 liters/ 1.4 liters/ 1.4 liters/

Front Axle Final Reduction 5.3 liters/ 5.3 liters/ 5.3 liters/
/Differential Gear Case . . . . . 5.6 U.S. qts. 5.6 U.S. qts. 5.6 U.S. qts.
00-31

COOLING SYSTEM
Type . . . . . . . . . . . . . . . . . . . . . Pressurized Liquid with Pressurized Liquid with Pressurized Liquid with
Recirculating Bypass Recirculating Bypass Recirculating Bypass
Water Pump:
Type . . . . . . . . . . . . . . . . . . . Centrifugal Centrifugal Centrifugal
Drive . . . . . . . . . . . . . . . . . . . V-Belt V-Belt V-Belt
Belt
Deflection . . . . . . . . . . . . . . . 10 mm-15 mm 10 mm-15 mm 10 mm-15 mm
(7/16″-9/16″) when (7/16″-9/16″) when (7/16″-9/16″) when
9-11 kg (20-25 lbs.) 9-11 kg (20-25 lbs.) 9-11 kg (20-25 lbs.)
thumb pressure is ap- thumb pressure is ap- thumb pressure is ap-
plied midway plied midway plied midway
between belt pulleys between belt pulleys between belt pulleys
Fan Diameter . . . . . . . . . . . . 410 mm (16.1″) 410 mm (16.1″) 410 mm (16.1″)
Number of Fan Blades . . . . 6 6 6
Thermostat:
Start to Open . . . . . . . . . . . . 71°C (160°F) 71°C (160°F) 71°C (160°F)
Fully Open . . . . . . . . . . . . . . 85°C (185°F) 85°C (185°F) 85°C (185°F)
Radiator Cap . . . . . . . . . . . . . 0.9 bar 0.9 bar 0.9 bar
(13 psi) (13 psi) (13 psi)
ELECTRICAL SYSTEM
Main System Protection . . . . 40 amp Maxifuse 40 amp Maxifuse 40 amp Maxifuse
Number Fuses for Circuit
Protection . . . . . . . . . . . . . . . . 7 7 7
Alternator . . . . . . . . . . . . . . . . 12-volt, Heavy Duty, 12-volt, Heavy Duty, 12-volt, Heavy Duty,
40 amps 40 amps 40 amps
Battery Type . . . . . . . . . . . . . . 12-volt, w/ negative 12-volt, w/ negative 12-volt, w/ negative
ground, 600 cca ground, 600 cca ground, 600 cca
Starter hp (KW) Rating 2.7 (2.0) 2.7 (2.0) 2.7 (2.0)
Battery Rating Amp Hrs. . . . . 64 -- 69 64 -- 69 64 -- 69
Starting Motor . . . . . . . . . . . . . Solenoid Solenoid Solenoid
Pre-Engaged Pre-Engaged Pre-Engaged
Reduction Reduction Reduction
FUEL SYSTEM
Fuel Type . . . . . . . . . . . . . . . . Diesel Diesel Diesel
Above 40°F . . . . . . . . . . . . . No. 2-Diesel, No. 2-Diesel, No. 2-Diesel,
Below 40°F . . . . . . . . . . . . . No. 1-Diesel, No. 1-Diesel, No. 1-Diesel,
Injection Pump:
Type . . . . . . . . . . . . . . . . . . . In-Line In-Line In-Line
Timing . . . . . . . . . . . . . . . . . . 20° BTDC 20° BTDC 18° BTDC
00-32

BRAKES
Type . . . . . . . . . . . . . . . . . . . . . Wet Disc Wet Disc Wet Disc
3 Disc Diameter . . . . . . . . . . . 175 mm x 143 mm 175 mm x 143 mm 175 mm x 143 mm
(6.9″ x 5.6″) (6.9″ x 5.6″) (6.9″ x 5.6″)
STEERING
Type . . . . . . . . . . . . . . . . . . . . . Power Power Power
Pump Flow @ Rated rpm . . . 19.4 lpm 19.4 lpm 19.4 lpm
(5.13 gpm) (5.13 gpm) (5.13 gpm)
Turns Lock-to-Lock:
FWD . . . . . . . . . . . . . . . . . . . 3.1/3.8 3.1/3.8 3.1/3.8
Front Wheel
Toe-In . . . . . . . . . . . . . . . . . . . . 0 mm -- 5 mm 0 mm -- 5 mm 0 mm -- 5 mm
(0″ -- 13/64″) (0″ -- 13/64″) (0″ -- 13/64″)
Turning Radius w/o Brakes:
FWD . . . . . . . . . . . . . . . . . . . 3238.5 mm (127.5″) 3238.5 mm (127.5″) 3238.5 mm (127.5″)
Max. Turn Angle:

FWD 54° 54° 54°
Front to rear axle ratio . . . . . . 1.660 to 1 1.660 to 1 1.660 to 1
POWER TAKE-OFF
Type . . . . . . . . . . . . . . . . . . . . . Independent Independent Independent
Shaft:
Rear PTO . . . . . . . . . . . . . . . 35 mm (1-3/8″) 35 mm (1-3/8″) 35 mm (1-3/8″)
Mid PTO . . . . . . . . . . . . . . . . 25.4 mm (1″) 25.4 mm (1″) N/A
Rear PTO Operation . . . . . . . 2400 rpm 2400 rpm 2400 rpm
Horsepower PTO Observed . 20.7 kw (27.7 hp) 24.3 kw (32.6 hp) 27.4 kw (36.7 hp)
Mid PTO Operation . . . . . . . . 2420 rpm 2420 rpm N/A
HYDRAULIC LIFT SYSTEM

Type . . . . . . . . . . . . . . . . . . . . . Open Center Open Center Open Center
Pump Type . . . . . . . . . . . . . . . Gear Gear Gear
Pump Capacity . . . . . . . . . . . . 37.1 lpm 37.1 lpm 37.1 lpm
(9.8 U.S. gpm) (9.8 U.S. gpm) (9.8 U.S. gpm)
System Relief Valve Setting . 160 bar 170 bar 170 bar
(2275 psi) (2500 psi) (2500 psi)
Number of Rear Remotes
Available . . . . . . . . . . . . . . . . . 3 (optional) 3 (optional) 3 (optional)
Number of Mid Remotes
Available . . . . . . . . . . . . . . . . . 2 (optional) 2 (optional) 2 (optional)
00-33

TRANSMISSION
Transmission Type . . . . . . . . (HST) (Hydrostatic) (HST) (Hydrostatic) (HST) (Hydrostatic)
Pump Displacement . . . . . . . 0.03 L (1.71 cu. in.) 0.03 L (1.71 cu. in.) 0.03 L (1.71 cu. in.)
Number of Motor Speeds . . . 2 2 2
Number of Transmission
Ranges . . . . . . . . . . . . . . . . . . 2 2 2
Motor Displacement -- High . 0.02 L (1.34 cu.in.) 0.02 L (1.34 cu.in.) 0.02 L (1.34 cu.in.)
Low . . 0.04 L (2.27 cu. in.) 0.04 L (2.27 cu. in.) 0.04 L (2.27 cu. in.)
Motor Hi/Lo Speed Shift Electric Switch Electric Switch Electric Switch
TRANSMISSION SPEEDS
Ag 13.6 x 24 rear @ Ag 13.6 x 24 rear @ Ag 13.6 x 24 rear @

2600 Rated rpm 2600 Rated rpm 2600 Rated rpm
Range I (Low), Motor LOW . . 0-5.61 kph Turtle 0-5.61 kph Turtle 0-5.61 kph Turtle
(0-3.49 mph) (0-3.49 mph) (0-3.49 mph)
Range I (High), Motor HI . . . . 0-9.49 kph Rabbit 0-9.49 kph Rabbit 0-9.49 kph Rabbit
(0-5.90 mph) (0-5.90 mph) (0-5.90 mph)
Range II (Low), Motor LOW . . 0-12.95 kph Turtle 0-12.95 kph Turtle 0-12.95 kph Turtle
(0-8.05 mph) (0-8.05 mph) (0-8.05 mph)
Range II (High), Motor HI . . . . 0-21.89 kph Rabbit 0-21.89 kph Rabbit 0-21.89 kph Rabbit
(0-13.60 mph) (0-13.60 mph) (0-13.60 mph)
00-34

CAST IRON WEIGHTS
Front End:
Ag, R-4 & Turf
Tires with
FWD . . . . . . . . . . . . . . (2) weights @ 29.7 kg (2) weights @ 29.7 kg (2) weights @ 29.7 kg
Optional (2) weights @ Optional (2) weights @ Optional (2) weights @

45 kg (100 lbs.) each 45 kg (100 lbs.) each 45 kg (100 lbs.) each
Standard FWD Axle:
(with extension bracket) . . . . (5) weights @ 26 kg (5) weights @ 26 kg (5) weights @ 26 kg
Total 26 kg (300 lbs.) Total 26 kg (300 lbs.) Total 26 kg (300 lbs.)
Or Or Or
(5) weights @ 45 kg (5) weights @ 45 kg (5) weights @ 45 kg

Total 225 kg (500 lbs.) Total 225 kg (500 lbs.) Total 225 kg (500 lbs.)
Rear Wheel:
R-4 Tires . . . . . . . . . . . . . . . . (4) weights (2) per (4) weights (2) per (4) weights (2) per
Turf Tires . . . . . . . . . . . . . . . --- --- ---
Ag. Tires . . . . . . . . . . . . . . . . (4) weights (2) per (4) weights (2) per (4) weights (2) per
DRAWBARS
Swinging/
Extendible . . . . . . . . . . . . . . . . Standard Standard Standard
3 POINT HITCH
Category Type . . . . . . . . . . . . I I I
Position Control Type . . . . . . Hydraulic Hydraulic Hydraulic
Draft Control Type . . . . . . . . . Top Link Sensing (DIA) Top Link Sensing (DIA) Top Link Sensing (DIA)
Drop Rate Control . . . . . . . . . Standard Standard Standard
Lift Capacity @ 24″
Behind kg (lbs.) . . . . . . . . . . . 920 (2025) 1059 (2330) 1059 (2330)
00-35

TIRES
FRONT:
Agricultural:
FWD . . . . . . . . . . . . . . . . . . . 7 x 16, 6PR, R1 7 x 16, 6PR, R1 7 x 16, 6PR, R1
8 x 16, 6PR, R1 8 x 16, 6PR, R1 8 x 16, 6PR, R11
Turf:
FWD . . . . . . . . . . . . . . . . . . . 27 x 8.5-15, 4PR, R3 27 x 8.5-15, 4PR, R3 27 x 8.5-15, 4PR, R3
Industrial:
FWD . . . . . . . . . . . . . . . . . . . 10 x 16.5, 6PR, R4 10 x 16.5, 6PR, R4 10 x 16.5, 6PR, R4
REAR:
Agricultural . . . . . . . . . . . . . . . 13.6 x 24, 4PR, R1 13.6 x 24, 4PR, R1 13.6 x 24, 4PR, R1
Turf . . . . . . . . . . . . . . . . . . . . . . 44 x 18-20, 4 PR, R3 44 x 18-20, 4 PR, R3 44 x 18-20, 4 PR, R3
Industrial . . . . . . . . . . . . . . . . . 17.5 x 24, 8PR, R4 17.5 x 24, 8PR, R4 17.5 x 24, 8PR, R4
WHEEL BOLT TORQUES

Front Wheel—
Disc-to-Hub:
FWD . . . . . . . . . . . . . . . . . . . 169 N⋅m 169 N⋅m 169 N⋅m
Rear Wheel—
Rear Wheel & Disc-to Axle . . 169 N⋅m 169 N⋅m 169 N⋅m
Disc-to Rim . . . . . . . . . . . . . . . 244 N⋅m 244 N⋅m 244 N⋅m

ROPS ATTACHING BOLT TORQUES

ROPS to Rear Axle 74 N⋅m 74 N⋅m 74 N⋅m
Seat Belt . . . . . . . . . . . . . . . . . 47.4 N⋅m 47.4 N⋅m 47.4 N⋅m
00-36
GENERAL DIMENSIONS
Model DX35 Model DX40 Model DX45
(1)—LENGTH Overall (Less 3 pt hitch) -- mm (in.)

2WD
sm AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . N/A N/A N/A
lg AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . . N/A N/A N/A
R4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A N/A N/A
TURF Tires . . . . . . . . . . . . . . . . . . . . . . . . . N/A N/A N/A
STD FWD
sm AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . 2955 (116.3) 2955 (116.3) 116.3 (2955)
lg AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 2971 (117) 2971 (117) 117 (2971)
R4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2960 (116.5) 2960 (116.5) 116.5 (2960)
TURF Tires . . . . . . . . . . . . . . . . . . . . . . . . . 2892 (113.9) 2892 (113.9) 113.9 (2892)
(1)—LENGTH Overall (3 pt hitch horizontal position) -- mm (in.)

2WD
sm AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . N/A N/A N/A
lg AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . . N/A N/A N/A
R4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . N/A N/A N/A
TURF Tires . . . . . . . . . . . . . . . . . . . . . . . . . N/A N/A N/A
STD FWD
sm AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 125.2 (3180)
lg AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 125.2 (3180)
R4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 125.2 (3180)
TURF Tires . . . . . . . . . . . . . . . . . . . . . . . . . 3180 (125.2) 3180 (125.2) 125.2 (3180)
00-37
(2)—WHEEL BASE:
FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1866.9 mm (73.5″) 1866.9 mm (73.5″) 1866.9 mm (73.5″)
lg AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 2057.4 mm (81.0″) 2057.4 mm (81.0″) 2057.4 mm (81.0″)
HEIGHTS -- mm (in.):
(3)—
ROPS Height - RIGID
sm AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . 2388 (94) 2388 (94) 2388 (94)
lg AG Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 (94.5) 2400 (94.5) 2400 (94.5)
R4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2400 (94.5) 2400 (94.5) 2400 (94.5)
TURF Tires . . . . . . . . . . . . . . . . . . . . . . . . . 2324 (91.5) 2324 (91.5) 2324 (91.5)
ROPS Height - FOLDING

sm AG Tires - Up . . . . . . . . . . . . . . . . . . . . 2400 (94.5) 2400 (94.5) 2400 (94.5)
sm AG Tires - Down . . . . . . . . . . . . . . . . . . 1956 (77) 1956 (77) 1956 (77)
lg AG Tires - Up . . . . . . . . . . . . . . . . . . . . . 2413 (95) 2413 (95) 2413 (95)
lg AG Tires - Down . . . . . . . . . . . . . . . . . . . 1969 (77.5) 1969 (77.5) 77.5 (1969)
R4 Tires - Up . . . . . . . . . . . . . . . . . . . . . . . . 2413 (95) 2413 (95) 2413 (95)
R4 Tires - Down . . . . . . . . . . . . . . . . . . . . . 1969 (77.5) 1969 (77.5) 1969 (77.5)
TURF Tires - Up . . . . . . . . . . . . . . . . . . . . . 2337 (92) 2337 (92) 2337 (92)
TURF Tires - Down . . . . . . . . . . . . . . . . . . . 1892 (74.5) 1892 (74.5) 1892 (74.5)
(4) --
Hood Height
(top inst. cluster)
sm AG FWD . . . . . . . . . . . . . . . . . . . . . . . . 1499 (59) 1499 (59) 1499 (59)
lg AG FWD . . . . . . . . . . . . . . . . . . . . . . . . . . 1511 (59.5) 1511 (59.5) 1511 (59.5)
R4 FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1524 (60) 1524 (60) 1524 (60)
TURF FWD . . . . . . . . . . . . . . . . . . . . . . . . . 1473 (58) 1473 (58) 1473 (58)
(5)—
Steering Wheel Height
sm AG FWD Variable Variable Variable
lg AG FWD . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Variable Variable
R4 FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . Variable Variable Variable
TURF FWD . . . . . . . . . . . . . . . . . . . . . . . . . Variable Variable Variable
(6) -- WIDTH:
Rear Axle—
Outside to Outside:
Turf Tires—
Dished In . . . . . . . . . . . . . . . . . . . . . . . . . . . 1823.7 mm (71.8″) 1823.7 mm (71.8″) 1823.7 mm (71.8″)
Dished Out . . . . . . . . . . . . . . . . . . . . . . . . . . 1846.6 mm (72.7″) 1846.6 mm (72.7″) 1846.6 mm (72.7″)
Ag. Tires— (Large)
Dished In . . . . . . . . . . . . . . . . . . . . . . . . . . . 1691.6 mm (66.6″) 1691.6 mm (66.6″) 1691.6 mm (66.6″)
R4 Tires—
Dished In . . . . . . . . . . . . . . . . . . . . . . . . . . . 2146.3 mm (84.5″) 2146.3 mm (84.5″) 2146.3 mm (84.5″)
00-38

(7)—GROUND CLEARANCE:
sm AG TIRES
(D.) - Minimum Centerline Clearance 330 (13) 330 (13) 330 (13)
(E.) - Frt Axle Crop Clear. - 15″ from CL 394 (15.5) 394 (15.5) 394 (15.5)
(F.) - Rr Axle Crop Clear. - 15″ from CL 445 (17.5) 445 (17.5) 445 (17.5)
lg AG TIRES
(F.) - Rr Axle Crop Clear. - 15″ from CL 457 (18) 457 (18) 457 (18)
R4 TIRES
(F.) - Rr Axle Crop Clear. - 15″ from CL 444 (17.5) 444 (17.5) 444 (17.5)
TURF TIRES
(D.) - Minimum Centerline Clearance 292 (11.5) 292 (11.5) 292 (11.5)
(E.) - Frt Axle Crop Clear. - 15″ from CL 330 (13) 330 (13) 330 (13)
(F.) - Rr Axle Crop Clear. - 15″ from CL 381 (15) 381 (15) 381 (15)
CL -- Center Line of Tractor
5 4
2
1
50045712
20035686
00-39

WHEEL TREAD SETTINGS:
FRONT AXLE:
Agricultural:
FWD 7 x 16 . . . . . . 1179.0 mm (46.4″) 1179.0 mm (46.4″) 1179.0 mm (46.4″)
8 x 16 . . . . . . 1179.0 mm (46.4″) 1179.0 mm (46.4″) 1179.0 mm (46.4″)
Turf:
FWD 25 x 8.5-14 1264.9 mm (49.8″) 1264.9 mm (49.8″) 1264.9 mm (49.8″)
Industrial:
FWD 10 x 16.5 . . . 1253 mm (49.3″) 1253 mm (49.3″) 1253 mm (49.3″)
REAR AXLE:
. - sm AG Tires 13.6 x 24
- MIN (Dished In) 1197 (47.1) 1197 (47.1) 1197 (47.1)
- MAX (Dished Out) 1712 (67.4) 1712 (67.4) 1712 (67.4)
- No. of available positions 6 6 6
- Adj. per person 102 (4) 102 (4) 102 (4)
. - lg AG Tires 14.9 x 24
- MIN (Dished In) 47.5 47.5 47.5
- MAX (Dished Out) 1712 (67.4) 1712 (67.4) 1712 (67.4)
- Adj. per person 102 (4) 102 (4) 102 (4)
. - R4 Tires 17.5 x 24
- MIN (Dished In) 1301 (51.2) 1301 (51.2) 1301 (51.2)
- MAX (Dished Out) 1712 (67.4) 1712 (67.4) 1712 (67.4)
- Adj. per person 102 (4) 102 (4) 102 (4)
. - TURF Tires 44 x 18 - 20
- MIN (Dished In) 1347 (53) 1347 (53) 1347 (53)
- MAX (Dished Out) 1368 (53.9) 1368 (53.9) 1368 (53.9)
- Only 2 available positions
WEIGHT (Bare Tractor):

With ROPS:
FWD . . . . . . . . . . . . . . . . . . . 1265 kg 1300 kg 1340 kg
(2784 lbs.) (2860 lbs.) (2949 lbs.)
00-40
MINIMUM HARDWARE TIGHTENING TORQUES

IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS
INCH HARDWARE AND LOCKNUTS

SAE GRADE 2 SAE GRADE 5 SAE GRADE 8 LOCKNUTS
NOMINAL UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED GR.B GR.C NOMINAL
SIZE or W/ZnCr or W/ZnCr or W/ZnCr w/GR5 w/GR8 SIZE
PLATED PLATED PLATED BOLT BOLT
SILVER GOLD SILVER GOLD SILVER GOLD
1/4 55* (6.2) 72* (8.1) 86* (9.7) 112* (13) 121* (14) 157* (18) 61* (6.9) 86* (9.8) 1/4
5/16 115* (13) 149* (17) 178* (20) 229* (26) 250* (28) 324* (37) 125* (14) 176* (20) 5/16
3/8 17 (23) 22 (30) 26 (35) 34 (46) 37 (50) 48 (65) 19 (26) 26 (35) 3/8
7/16 27 (37) 35 (47) 42 (57) 54 (73) 59 (80) 77 (104) 30 (41) 42 (57) 7/16
1/2 42 (57) 54 (73) 64 (87) 83 (113) 91 (123) 117 (159) 45 (61) 64 (88) 1/2
9/16 60 (81) 77 (104) 92 (125) 120 (163) 130 (176) 169 (229) 65 (88) 92 (125) 9/16
5/8 83 (112) 107 (145) 128 (174) 165 (224) 180 (244) 233 (316) 90 (122) 127 (172) 5/8
3/4 146 (198) 189 (256) 226 (306) 293 (397) 319 (432) 413 (560) 160 (217) 226 (306) 3/4
7/8 142 (193) 183 (248) 365 (495) 473 (641) 515 (698) 667 (904) 258 (350) 364 (494) 7/8
1 213 (289) 275 (373) 547 (742) 708 (960) 773 (1048) 1000 (1356) 386 (523) 545 (739) 1
NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION
CAP SCREWS AND CARRIAGE BOLTS
SAE GRADE 2 SAE GRADE 5 SAE GRADE 8
REGULAR NUTS SAE GRADE 5 SAE GRADE 8

HEX NUTS HEX NUTS
LOCKNUTS
GRADE IDENTIFICATION GRADE IDENTIFICATION

GRADE A NO NOTCHES GRADE A NO MARKS
GRADE B ONE CIRCUMFERENTIAL NOTCH GRADE B THREE MARKS
GRADE C TWO CIRCUMFERENTIAL NOTCHES GRADE C SIX MARKS

MARKS NEED NOT BE LOCATED
AT CORNERS
GRADE A NO MARK
GRADE B LETTER B
GRADE C LETTER C
GRADE IDENTIFICATION
00-41
MINIMUM HARDWARE TIGHTENING TORQUES

IN FOOT POUNDS (NEWTON-METERS) FOR NORMAL ASSEMBLY APPLICATIONS
METRIC HARDWARE AND LOCKNUTS

CLASS 5.8 CLASS 8.8 CLASS 10.9 LOCKNUT
NOMINAL CL.8
SIZE UNPLATED PLATED UNPLATED PLATED UNPLATED PLATED W/CL8.8
W/ZnCr W/ZnCr W/ZnCr BOLT
M4 15* (1.7) 19* (2.2) 23* (2.6) 30* (3.4) 33* (3.7) 42* (4.8) 16* (1.8)
M6 51* (5.8) 67* (7.6) 79* (8.9) 102* (12) 115* (13) 150* (17) 56* (6.3)
M8 124* (14) 159* (18) 195* (22) 248* (28) 274* (31) 354* (40) 133* (15)
M10 21 (28) 27 (36) 32 (43) 41 (56) 45 (61) 58 (79) 22 (30)
M12 36 (49) 46 (63) 55 (75) 72 (97) 79 (107) 102 (138) 39 (53)
M16 89 (121) 117 (158) 137 (186) 177 (240) 196 (266) 254 (344) 97 (131)
M20 175 (237) 226 (307) 277 (375) 358 (485) 383 (519) 495 (671) 195 (265)
M24 303 (411) 392 (531) 478 (648) 619 (839) 662 (897) 855 (1160) 338 (458)
NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION
HEX CAP SCREW AND CARRIAGE BOLTS
CLASSES 5.6 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS
HEX NUTS AND LOCKNUTS

CLASSES 05 AND UP
MANUFACTURER’S IDENTIFICATION
PROPERTY CLASS CLOCK MARKING
00-42
SPECIAL TOOLS
Gauge -- (0-3000 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OEM 1462

Gauge -- (6000 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OEM 1464
Gauge -- (300 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OEM 1457
Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procure Locally
Tee Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #CNH299061, CIH #CAS2793)
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #FNH00227, CIH #CAS2794)
Male Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Included with (NH #CNH299061, CIH #CAS2793)
Female Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Included with (NH #CNH299061, CIH #CAS2793)
Variseal Installation Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293955
Detent Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #FNH00081, CIH #CAS2788)
Seal Driver Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #FNH00293, CIH #CAS2785)
Injector Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #FNH01721, CIH #OEM1064)
Injector Adapter Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #FNH01728, CIH #OEM23622)
Clutch Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #FNH299006, CIH #CAS2786)
Engine Compression Test Adapter . . . . . . . . . . . . . . . . . . . (NH #FNH00120, CIH #CAS2776)
Engine Compression Test Gauge Assembly . . . . . . . . . . . OEM1074
Oil Pump Port Block Remover Tool . . . . . . . . . . . . . . . . . . . (NH #FNH11097, CIH #CAS2779)
Oil Pump Port Block Installer Tool . . . . . . . . . . . . . . . . . . . . (NH #FNH00117, CIH #CAS2778)
Oil Pump Port Block Remover Sleeve (Pair) . . . . . . . . . . . FNH11099
Oil Pump Port Block Installer Pins . . . . . . . . . . . . . . . . . . . . FNH11044
Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 -- 25 mm (0 -- 1 in.)
Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 -- 51 mm (1 -- 2 in.)
Micrometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 -- 76 mm (2 -- 3 in.)
Small Hole Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 -- 25 mm (3/4 -- 1 in.)
Cylinder Bore Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 -- 76 mm (2 -- 3 in.)
Cylinder Bore Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 -- 51 mm (1 -- 2 in.)
HST High Pressure Test Fitting . . . . . . . . . . . . . . . . . . . . . . (NH #CNH299007, CIH #CAS2787)
Engine Oil Pressure Test Fitting . . . . . . . . . . . . . . . . . . . . . (NH #FNH00011, CIH #CAS2791)
PTO Clutch Pack Pressure Test Fitting . . . . . . . . . . . . . . . (NH #CNH299008, CIH #CAS2789)
PTO Clutch Pack Press Tool . . . . . . . . . . . . . . . . . . . . . . . . (NH #CNH299009, CIH #CAS2790)
00-43
RECOMMENDED LUBRICANTS
Lubricant Location Used Type Case IH No. Amount
Oil Engine and Pivot Points without 10W--30 104104A1 1--quart
Grease Fittings, Chains
104106A1 5--gallons
139033A1 1--gallon
15W--40 407410R2 1--quart
407414R2 5--gallons
Coolant Engine Ethylene Coolant Concentrate
Hydraulic Oil Hydraulic System HY -- Tran Ultra 139029A2 1--gallon
Hydrostatic System
Transmission
Front Axle
Rear Axle
Power Steering
143945A2 2.5--gallons
372705R7 5--gallons
Gear Oil Gearboxes 80W90 SAE API GL5 135H EP Gear Lube
Grease All Grease Fittings High Viscosity Lithium Base--NLGI#2 132096A1 Cartridge
00-44
ADJUSTMENTS
FRONT TIRE INFLATION PRESSURES
Tire Type Tire Size Inflation Pressure
Agricultural:
2WD 5.50 x 16, 4PR, F2 0.6 -- 1.4 bar (8 -- 20 psi)
7.5 x 15, 6 PR
FWD 7 x 16, 6PR, R1 0.6 -- 1.4 bar (8 -- 20 psi)

8 x 16, 6PR, R1 1.4 -- 1.7 bar (20 -- 24 psi)
Turf:
2WD 25 x 8.50-14, 4PR, R3 0.6 -- 0.8 bar (8 -- 12 psi)
FWD 27 x 8.50-15, 4PR, R3
Industrial (FWD only) 10 x 16.5, 6PR, R4 (16 -- 45 psi)
REAR TIRE INFLATION PRESSURES
Agricultural 13.6 x 24, 4PR, R1 0.8 -- 0.97 bar (12 -- 14 psi)
Turf 44 x 18-20, 4PR, R3 (12 -- 20 psi)
Industrial (R4) 17.5 x 24, 6PR, R4 (12 -- 26 psi)
00-45
Op. 00 100
PRE-SEASON AND PRE-DELIVERY SERVICE
INOPERATIVE SERVICE CHECKS SAFETY ITEMS CHECKS

1. ____ Tire Pressure 1. ____ ROPS Installed
2. ____ Air Cleaner Element & Hose Connections 2. ____ Seat Belts Installed
3. ____ Radiator Coolant Level 3. ____ ROPS Bolt Torque -- 74.5 N⋅m (55 ft. lbs.);
Seat Belt Bolt Torque -- 47.4 N⋅m (35 ft. lbs.)
4. ____ Fan Belt Tension
4. ____ PTO Shield Installed
5. ____ Battery Cleanliness, Vent Openings,
Electrolyte Level, & Charge 5. ____ SMV Emblem Installed
6. ____ Engine Oil Level 6. ____ Safety Decals Installed
7. ____ Power Steering Reservoir Oil Level 7. ____ Neutral Start Switches Operation
8. ____ Transmission & Rear Axle Oil Level 8. ____ Parking Brake & Latch Operation
9. ____ Front Axle & Final Reduction Gear 9. ____ Flashing Lights/Tail Lights Operation
Case Oil Level (FWD)
10.____Operator’s Manual (present)
10.____Hydraulic Lift Control Drop Manual #87300517 --
Rate Adjustment D35, D40, D45
11.____ Top Link (present) Manual #87300519 --

DX35, DX40, DX45
12.____Brake Adjustment & Pedal Equalization
13.____Clutch Pedal Free Play (D35, D40, D45) OPERATIVE SERVICE CHECKS
All operating checks are to be performed with tractor
14.____Rear Wheel Bolt Torque -- 169 N⋅m at normal operating temperature.
(125 ft. lbs.)
1. ____ Lights & Instruments for Proper Operation,
15.____Front Wheel Bolt Torque -- 169 N⋅m & Fuel Shut Down with Key Switch OFF
(125 ft. lbs.) (2WD & FWD)
2. ____ Fluid & Oil Leaks
16.____Front Wheel Toe-in
3. ____ Maximum No-load Speed & Idle
17.____Fuel Level Speed Adjustments
(Max: 2855 rpm, Idle: 1025 rpm)
18.____Sheet Metal & Paint Condition
4. ____ PTO Engagement & Disengagement
19.____Seat Function ____ Clutch Pedal & PTO Lever
5. Hydraulic System:
____ Selector Lever for Position Control
____ Flow Control Operation
6. ____ FWD -- Drive Lever Operation
7. ____ Operation of H.S.T. (DX35, DX40, DX45)
00-46
SECTION 10 -- ENGINE -- CHAPTER 1
SECTION 10 - ENGINE
Chapter 1 - Engine
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Metric Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Compression Test and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cylinder Head and Valve Train Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Separating the Tractor at the Clutch Housing/Engine -- 12 x 12 Transmission . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Separating the Tractor at the HST Housing/Engine -- HST Transmission . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Separating the Tractor at the Engine Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Attaching the HST to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fuel Injector and Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Temperature Sending Switch and Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Fan, Water Pump and External Oil Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Air Inlet Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Rocker Arm Shaft and Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10 101 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
10-1

Valve Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10 106 Engine Timing Gear Cover, Timing Gears and Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . 57
Timing Gear Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10 106 Timing Gears and Cam Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10 102 Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Oil Suction Pipe and Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10 105 Connecting Rods, Bearings and Pistons, Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10 103 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 103 Backplate and Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Crankshaft and Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 101 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Valve Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Push Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10 105 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Disassembly and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting Rod Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Clearance Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10-2

Pistons, Rings and Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
10 103 Crankshaft -- Main Bearing and Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Removal and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Bearing (Bushing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10 106 Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10 103 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10 102 Timing Gear Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10 102 Front Oil Seal and Steering Pump Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
10 103 Crankshaft and Bearing Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Rear Oil Seal and Backplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10 105 Pistons and Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Balancer Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Oil Suction Pipe and Suction Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Oil Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10 106 Camshaft and Camshaft Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10-3

10 106 Idler Gear, Oil Pump and Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Timing Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Hydraulic Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10 101 Head Gasket Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Selection Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10 106 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Water Pump and Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
External Oil Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Glow Plug and Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10 218 Fuel Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Alternator and Temperature Sender Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10 304 Description of Operation -- Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10 206 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Construction and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10-4

10 304 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Installation and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Oil Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
10 400 Description of Operation -- Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Radiator Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
10 402 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10 402 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
10 414 Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Overhaul -- Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
10 406 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
10 402 Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
10 402 Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cab Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
10-5
SPECIFICATIONS
GENERAL D35, DX35 D40, DX40 D45, DX45

Engine Model N843L N844 N844L
Number of Cylinders 3 4 4
84 x 100 mm 84 x 90 mm 84 x 100 mm
Bore x Stroke
(3.31 x 3.94 in.) (3.31 x 3.54 in.) (3.31 x 3.94 in.)
1622 cc 1995 cc 2216 cc
Displacement
(101.4 cu. in.) (121.7 cu. in.) (135.2 cu. in.)
Compression Ratio 22.5:1 22.5:1 22.5:1
Rated Speed (rpm) 2600 2600 2600
Muffler Horizontal
Firing Order 1-2-3 1-3-4-2 1-3-4-2
Low Idle Speed 1050 rpm 1050 rpm 1050 rpm
Maximum No-Load Speed 2840 rpm 2840 rpm 2840 rpm
Cylinder Arrangement In-Line Vertical In-Line Vertical In-Line Vertical
Valve Arrangement Overhead Overhead Overhead
Compression Pressure 29.4 ± 1.8 bar 29.4 ± 1.8 bar 29.4 ± 1.8 bar
at 200 rpm (cylinder speed) (427 ± 50 psi) (427 ± 50 psi) (427 ± 50 psi)
Variation between cylinders
CYLINDER BLOCK N843L N844 N844L
Bore
84.0 mm 84.0 mm 84.0 mm
Standard
(3.3071-3.3078 in.) (3.3071-3.3078 in.) (3.3071-3.3078 in.)
85.2 mm 85.2 mm 85.2 mm
Maximum
(3.3543 in.) (3.3543 in.) (3.3543 in.)
Head Surface Warp
.05 mm .05 mm .05 mm
Standard
(.002 in.) (.002 in.) (.002 in.)
.12 mm .12 mm .12 mm
Maximum
(.005 in.) (.005 in.) (.005 in.)
* If bore size exceeds 85.2 mm (3.3543 in.) replace with long block.
10-6
CYLINDER HEAD N843L N844 N844L

Head Warp
0.05 mm 0.05 mm 0.05 mm
Standard
(0.002 in. less than) (0.002 in.) (0.002 in.)
0.12 mm 0.12 mm 0.12 mm
Maximum
(0.005 in.) (0.005 in.) (0.005 in.)
Valve Seat Width
1.7-2.1 mm 1.7-2.1 mm 1.7-2.1 mm
Standard
(0.067-0.082 in.) (0.067-0.082 in.) (0.067-0.082 in.)
2.5 mm 2.5 mm 2.5 mm
Maximum
(0.098 in.) (0.098 in.) (0.098 in.)
Valve Seat Sink
0.85-1.15 mm 0.85-1.15 mm 0.85-1.15 mm
Standard (Recess)
(0.0334-0.0453 in.) (0.0334-0.0453 in.) (0.0334-0.0453 in.)
1.8 mm 1.8 mm 1.8 mm
Maximum
(0.071 in.) (0.071 in.) (0.071 in.)
Valve Angle 45° 45° 45°
PISTON N843L N844 N844L
Diameter
83.948-83.963 mm 83.948-83.963 mm 83.948-83.963 mm
Standard
(3.30503-3.30562 in.) (3.30503-3.30562 in.) (3.30503-3.30562 in.)
83.7 mm 83.7 mm 83.7 mm
MInimum
(3.2953 in.) (3.2953 in.) (3.2953 in.)
Bore Clearance
0.038-0.072 mm 0.038-0.072 mm 0.038-0.072 mm
Standard
(0.0014-0.0028 in.) (0.0014-0.0028 in.) (0.0014-0.0028 in.)
0.25 mm 0.25 mm 0.25 mm
Maximum
(0.010 in.) (0.010 in.) (0.010 in.)
Piston Pin Bore
27.996-28.000 mm 27.996-28.000 mm 27.996-28.000 mm
Standard
(1.102-1.1023 in.) (1.102-1.1023 in.) (1.102-1.1023 in.)
27.98 mm 27.98 mm 27.98 mm
Maximum
(1.102 in.) (1.102 in.) (1.102 in.)
Piston Pin Clearance
--0.001 + 0.007 mm --0.001 + 0.007 mm --0.001 + 0.007 mm
Standard
(--0.000393 +0 .0002 in.) (--0.000393 +0 .0002 in.) (--0.000393 +0 .0002 in.)
0.02 mm 0.02 mm 0.02 mm
Maximum
(0.0008 in.) (0.0008 in.) (0.0008 in.)
10-7
PISTON PIN N843L N844 N844L

Diameter
27.996-28.0 mm 27.996-28.0 mm 27.996-28.0 mm
Standard
(1.1022-1.10236 in.) (1.1022-1.10236 in.) (1.1022-1.10236 in.)
27.98 mm 27.98 mm 27.98 mm
Minimum
(1.1016 in.) (1.1016 in.) (1.1016 in.)
Pin-to-Bushing Clearance
0.01-0.025 mm 0.01-0.025 mm 0.01-0.025 mm
Standard
(0.00039-0.00098 in.) (0.00039-0.00098 in.) (0.00039-0.00098 in.)
0.08 mm 0.08 mm 0.08 mm
Maximum
(0.0031 in.) (0.0031 in.) (0.0031 in.)
PISTON RING N843L N844 N844L
End Gap
0.2-0.35 mm 0.2-0.35 mm 0.2-0.35 mm
1st Ring
(0.008-0.0138 in.) (0.008-0.0138 in.) (0.008-0.0138 in.)
1.0 mm 1.0 mm 1.0 mm
Maximum
(0.039 in.) (0.039 in.) (0.039 in.)
0.20-0.40 mm 0.20-0.40 mm 0.20-0.40 mm
2nd Ring
(0.0079-0.0157 in.) (0.0079-0.0157 in.) (0.0079-0.0157 in.)
1.0 mm 1.0 mm 1.0 mm
Maximum
(0.039 in.) (0.039 in.) (0.039 in.)
0.20-0.80 mm 0.20-0.80 mm 0.20-0.80 mm
Oil Ring
(0.0079-0.0315 in.) (0.0079-0.0315 in.) (0.0079-0.0315 in.)
1.2 mm 1.2 mm 1.2 mm
Maximum
(0.047 in.) (0.047 in.) (0.047 in.)
Compression
Ring-to-Groove Clearance
0.7-0.11 mm 0.7-0.11 mm 0.7-0.11 mm
Standard (1st Ring)
(0.0027-0.0043 in.) (0.0027-0.0043 in.) (0.0027-0.0043 in.)
0.04-0.08 mm 0.04-0.08 mm 0.04-0.08 mm
2nd Ring
(0.0015-0.0031 in.) (0.0015-0.0031 in.) (0.0015-0.0031 in.)
0.25 mm 0.25 mm 0.25 mm
Maximum
(0.010 in.) (0.010 in.) (0.010 in.)
Oil Ring-to-Groove Clearance
0.03-0.13 mm 0.03-0.13 mm 0.03-0.13 mm
Standard
(0.001-0.00512 in.) (0.001-0.00512 in.) (0.001-0.00512 in.)
0.25 mm 0.25 mm 0.25 mm
Maximum
(0.010 in.) (0.010 in.) (0.010 in.)
Ring Width
2.0 mm 2.0 mm 2.0 mm
1st Compression
(0.079 in.) (0.079 in.) (0.079 in.)
1.5 mm 1.5 mm 1.5 mm
2nd Compression
(0.059 in.) (0.059 in.) (0.059 in.)
4.0 mm 4.0 mm 4.0 mm
Oil Compression
(0.157 in.) (0.157 in.) (0.157 in.)
10-8
CONNECTING ROD N843L N844 N844L

Rod Twist
0.08 mm 0.08 mm 0.08 mm
Standard
(0.003 in.) (0.003 in.) (0.003 in.)
0.2 mm 0.2 mm 0.2 mm
Maximum
(0.008 in.) (0.008 in.) (0.008 in.)
Rod Bend
0.05 mm 0.05 mm 0.05 mm
Standard
(0.002 in.) (0.002 in.) (0.002 in.)
0.15 mm 0.15 mm 0.15 mm
Maximum
(0.059 in.) (0.059 in.) (0.059 in.)
On Crankshaft Side Play
0.1-0.3 mm 0.1-0.3 mm 0.1-0.3 mm
Standard
(0.004-0.012 in.) (0.004-0.012 in.) (0.004-0.012 in.)
0.7 mm 0.7 mm 0.7 mm
Maximum
(0.028 in.) (0.028 in.) (0.028 in.)
Crankshaft Bearing Clearance
0.035-0.083 mm 0.035-0.083 mm 0.035-0.083 mm
Standard
(0.0014-0.00327 in.) (0.0014-0.00327 in.) (0.0014-0.00327 in.)
0.2 mm 0.2 mm 0.2 mm
Maximum
(0.008 in.) (0.008 in.) (0.008 in.)
CRANKSHAFT N843L N844 N844L
Journal Diameter
67.957-67.97 mm 67.957-67.97 mm 67.957-67.97 mm
Standard
(2.6754-2.676 in.) (2.6754-2.676 in.) (2.6754-2.676 in.)
67.9 mm 67.9 mm 67.9 mm
Maximum
(2.673 in.) (2.673 in.) (2.673 in.)
Crankpin Diameter
51.964-51.975 mm 51.964-51.975 mm 51.964-51.975 mm
Standard
(2.0458-2.0462 in.) (2.0458-2.0462 in.) (2.0458-2.0462 in.)
51.9 mm 51.9 mm 51.9 mm
Maximum
(2.043 in.) (2.043 in.) (2.043 in.)
Runout
0.03 mm 0.03 mm 0.03 mm
Standard
(0.0012 in.) (0.0012 in.) (0.0012 in.)
0.06 mm 0.06 mm 0.06 mm
Maximum
(0.0023 in.) (0.0023 in.) (0.0023 in.)
Endplay
0.1-0.4 mm 0.1-0.4 mm 0.1-0.4 mm
Standard
(0.0039-0.0156 in.) (0.0039-0.0156 in.) (0.0039-0.0156 in.)
0.5 mm 0.5 mm 0.5 mm
Maximum
(0.0195 in.) (0.0195 in.) (0.0195 in.)
10-9
CRANKSHAFT (continued) N843L N844 N844L

Thrust Washer
Thickness
2.95-3.0 mm 2.95-3.0 mm 2.95-3.0 mm
Standard
(0.115-0.117 in.) (0.115-0.117 in.) (0.115-0.117 in.)
2.8 mm 2.8 mm 2.8 mm
Minimum
(0.109 in.) (0.109 in.) (0.109 in.)
Cylinder Block Bearing
Diameter
68 x 72 mm 68 x 72 mm 68 x 72 mm
Standard
(2.677 x 2.418 in.) (2.677 x 2.418 in.) (2.677 x 2.418 in.)
Journal-to-Cylinder
Block Bearing Clearance
0.044-0.116 mm 0.044-0.116 mm 0.044-0.116 mm
Standard
(0.0017-0.0046 in.) (0.0017-0.0046 in.) (0.0017-0.0046 in.)
0.2 mm 0.2 mm 0.2 mm
Maximum
(0.079 in.) (0.079 in.) (0.079 in.)
Main Journal Regrind
Size
0.25 mm (0.010) 67.707-67.720 mm 67.707-67.720 mm 67.707-67.720 mm
undersize (2.6656-2.6661 in.) (2.6656-2.6661 in.) (2.6656-2.6661 in.)
67.65 mm 67.65 mm 67.65 mm
Maximum
(2.663 in.) (2.663 in.) (2.663 in.)
0.50 mm (0.020) 67.457-67.470 mm 67.457-67.470 mm 67.457-67.470 mm
67.4 mm 67.4 mm 67.4 mm
Maximum
(*2.238 in.) (*2.238 in.) (*2.238 in.)
Crankpin Regrind Size
0.25 mm (0.010) 51.714-51.725 mm 51.714-51.725 mm 51.714-51.725 mm
51.65 mm 51.65 mm 51.65 mm
Maximum
(2.0335 in.) (2.0335 in.) (2.0335 in.)
0.50 mm (0.020) 51.464-51.475 mm 51.464-51.475 mm 51.464-51.475 mm
51.40 mm 51.40 mm 51.40 mm
Maximum
(2.2024 in.) (2.2024 in.) (2.2024 in.)
Center Bearing to
Crankshaft Clearance
0.044-0.102 mm 0.044-0.102 mm 0.044-0.102 mm
Standard
(0.001732-0.004016 in.) (0.001732-0.004016 in.) (0.001732-0.004016 in.)
0.2 mm 0.2 mm 0.2 mm
Maximum
(0.079 in.) (0.079 in.) (0.079 in.)
Dynamic Balancer
Counterweight gear 0.2-0.4 mm 0.2-0.4 mm
backlash (0.008-0.016 in.) (0.008-0.016 in.)
0.4 mm 0.4 mm
Maximum
(0.016 in.) (0.016 in.)
* Center Bearing to Crankshaft Clearance
10-10
CAMSHAFT N843L N844 N844L

Cam Height-Valve
34.433-34.508 mm 34.433-34.508 mm 34.433-34.508 mm
Standard
(1.3564-1.3586 in.) (1.3564-1.3586 in.) (1.3564-1.3586 in.)
34.1 mm 34.1 mm 34.1 mm
Minimum
(1.3425 in.) (1.3425 in.) (1.3425 in.)
Bend
0.03 mm 0.03 mm 0.03 mm
Standard
(0.001 in.) (0.001 in.) (0.001 in.)
0.1 mm 0.1 mm 0.1 mm
Maximum
(0.004 in.) (0.004 in.) (0.004 in.)
Cam Height-Fuel
42.94-43.06 mm 42.94-43.06 mm 42.94-43.06 mm
Standard
(1.6905-1.6953 in.) (1.6905-1.6953 in.) (1.6905-1.6953 in.)
42.8 mm 42.8 mm 42.8 mm
Minimum
(1,6850 in.) (1,6850 in.) (1,6850 in.)
VALVES N843L N844 N844L
Stem Diameter-Intake
6.95-6.97 mm 6.95-6.97 mm 6.95-6.97 mm
Standard
(0.2738-0.2744 in.) (0.2738-0.2744 in.) (0.2738-0.2744 in.)
6.89 mm 6.89 mm 6.89 mm
Minimum
(0.271 in.) (0.271 in.) (0.271 in.)
Stem Diameter-Exhaust
6.94-6.95 mm 6.94-6.95 mm 6.94-6.95 mm
Standard
(0.273-0.274 in.) (0.273-0.274 in.) (0.273-0.274 in.)
6.84 mm 6.84 mm 6.84 mm
Minimum
(0.269 in.) (0.269 in.) (0.269 in.)
Guide Clearance-Intake
0.03-0.06 mm 0.03-0.06 mm 0.03-0.06 mm
Standard
(0.001-0.002 in.) (0.001-0.002 in.) (0.001-0.002 in.)
0.2 mm 0.2 mm 0.2 mm
Maximum
(0.008 in.) (0.008 in.) (0.008 in.)
Guide Clearance-Exhaust
0.0451--0.075 mm 0.0451--0.075 mm 0.0451--0.075 mm
Standard
(0.0018-0.0029 in.) (0.0018-0.0029 in.) (0.0018-0.0029 in.)
0.25 mm 0.25 mm 0.25 mm
Maximum
(0.01 in.) (0.01 in.) (0.01 in.)
Valve Margin (Thickness)
0.775-1.075 mm 0.775-1.075 mm 0.775-1.075 mm
Standard
(0.0305-0.0423 in.) (0.0305-0.0423 in.) (0.0305-0.0423 in.)
0.5 mm 0.5 mm 0.5 mm
Minimum
(0.0197 in.) (0.0197 in.) (0.0197 in.)
0.2 mm 0.2 mm 0.2 mm
Valve Lash Cold Condition
(0.008 in.) (0.008 in.) (0.008 in.)
10-11
VALVES (continued) N843L N844 N844L

Valve Spring-Free Height
35 mm 35 mm 35 mm
Standard
(1.378 in.) (1.378 in.) (1.378 in.)
33.5 mm 33.5 mm 33.5 mm
Minimum
(1.319 in.) (1.319 in.) (1.319 in.)
Valve Spring-Squareness
1.2 mm 1.2 mm 1.2 mm
Standard
(0.0472 in.) (0.0472 in.) (0.0472 in.)
2.0 mm 2.0 mm 2.0 mm
Maximum
(0.079 in.) (0.079 in.) (0.079 in.)
Valve Timing-Intake
Open Before TDC 10° 10° 10°
Close After BDC 46° 46° 46°
Valve Timing-Exhaust
Open Before TDC 40° 40° 40°
Close After BDC 16° 16° 16°
Valve Spring-Compressed
Load Required to Compress
Spring to 30.4 mm (1.2 in.)
8.1 kg 8.1 kg 8.1 kg
Standard
(17.85 lbs.) (17.85 lbs.) (17.85 lbs.)
7 kg 7 kg 7 kg
Minimum
(15.43 lbs.) (15.43 lbs.) (15.43 lbs.)
PUSH RODS N843L N844 N844L
225.6 - 226.4 mm 205.1 - 205.9 mm 225.6 - 226.4 mm
Length
(8.882 - 8.913 in.) (8.075 - 8.11 in.) (8.882 - 8.913 in.)
6.3 mm 6.3 mm 6.3 mm
Diameter
(0.248 in.) (0.248 in.) (0.248 in.)
ROCKER ARM N843L N844 N844L
Shaft Diameter
14.95 - 14.968 mm 14.95 - 14.968 mm 14.95 - 14.968 mm
Standard
(0.5886 - 0.5893 in.) (0.5886 - 0.5893 in.) (0.5886 - 0.5893 in.)
14.87 mm 14.87 mm 14.87 mm
Minimum
(0.585 in.) (0.585 in.) (0.585 in.)
Shaft-to-Rocker Clearance
0.032-0.068 mm 0.032-0.068 mm 0.032-0.068 mm
Standard
(0.00126-0.00268 in.) (0.00126-0.00268 in.) (0.00126-0.00268 in.)
0.2 mm 0.2 mm 0.2 mm
Maximum
(0.008 in.) (0.008 in.) (0.008 in.)
10-12
LUBRICATION SYSTEM N843L N844 N844L

Pressure Relief Valve
2.9-3.4 bar 2.9-3.4 bar 2.9-3.4 bar
Opening Pressure
(42.66-49.7 psi) (42.66-49.7 psi) (42.66-49.7 psi)
4.9 bar 4.9 bar 4.9 bar
Fully Open at 3000 rpm
(71.1 psi) (71.1 psi) (71.1 psi)
Rotor-to-Vane Clearance
0.1-0.15 mm 0.1-0.15 mm 0.1-0.15 mm
Standard
(0.004-0.006 in.) (0.004-0.006 in.) (0.004-0.006 in.)
0.25 mm 0.25 mm 0.25 mm
Maximum
(0.010 in.) (0.010 in.) (0.010 in.)
Rotor-to-Cover Clearance
0.1-0.15 mm 0.1-0.15 mm 0.1-0.15 mm
Standard
(0.004-0.006 in.) (0.004-0.006 in.) (0.004-0.006 in.)
0.20 mm 0.20 mm 0.20 mm
Maximum
(0.008 in.) (0.008 in.) (0.008 in.)
Oil Pump Volume 3.2 L (0.8 gal.) 4.5 L (1.18 gal.) 4.5 L (1.18 gal.)
COOLING SYSTEM
Type of System Pressurized liquid w/recirculating by-pass
Water Pump Centrifugal
5-10 mm (0.2-0.4 inch) when 5 kg (2.3 lbs.) force is applied midway
Drive Belt Deflection (Tension)
between pulleys.
Thermostat
Starts to Open 80-84°C (176-183°F)
Fully Open 95°C (203°F)
Radiator Cap Pressure Rating 0.9 bar (13 psi)
Coolant Ethylene glycol and water in a 50/50 mixture.
N843L N844 N844L
Capacity 7.4 liters 7.9 liters 8.0 liters
(7.8 U.S. qts.) (8.3 U.S. qts.) (8.4 U.S. qts.)
10-13
TORQUE SPECIFICATION N843L N844 N844L

49--54 N⋅m 49--54 N⋅m 49--54 N⋅m
Connecting Rod Cap Bolts
(36-40 lbs. ft.) (36-40 lbs. ft.) (36-40 lbs. ft.)
49--54 N⋅m 49--54 N⋅m 49--54 N⋅m
Main Bearing Retaining Bolts
59-69 N⋅m 59-69 N⋅m 59-69 N⋅m
Relief Valve Assembly
Crankshaft Main Bearing
Holder Bolts
25-29 N⋅m 25-29 N⋅m 25-29 N⋅m
Rear Main
49-54 N⋅m 49-54 N⋅m 49-54 N⋅m
Center Mains
12-17 N⋅m 12-17 N⋅m 12-17 N⋅m
Engine Rear Mounting Plate
68-78 N⋅m 68-78 N⋅m 68-78 N⋅m
Flywheel Retaining Bolts
9-12 N⋅m 9-12 N⋅m 9-12 N⋅m
Engine Front Plate
274-333 N⋅m 274-333 N⋅m 274-333 N⋅m
Crankshaft Pulley Nut
98-103 N⋅m 98-103 N⋅m 98-103 N⋅m
Cylinder Head Bolts
(72.3-76 lbs. ft.) (72.3-76 lbs. ft.) (72.3-76 lbs. ft.)
27-39 N⋅m 27-39 N⋅m 27-39 N⋅m
Rocker Arm Assembly
11-16 N⋅m 11-16 N⋅m 11-16 N⋅m
Rocker Arm Locknut
9-13 N⋅m 9-13 N⋅m 9-13 N⋅m
Oil Tube Banjo Bolt
14-20 N⋅m 14-20 N⋅m 14-20 N⋅m
Oil Pressure Switch
10-14 lbs. ft.) 10-14 lbs. ft.) 10-14 lbs. ft.)
7-12 N⋅m 7-12 N⋅m 7-12 N⋅m
Rocker Cover Bolts
14-20 N⋅m 14-20 N⋅m 14-20 N⋅m
Glow Plugs
9-13 N⋅m 9-13 N⋅m 9-13 N⋅m
Cooling Fan Bolts
(6.5-9 lbs. ft.) (6.5-9 lbs. ft.) (6.5-9 lbs. ft.)
Balancer
49-53.9 N⋅m 49-53.9 N⋅m
Retaining Bolts
(36-39 lbs. ft.) (36-39 lbs. ft.)
10-14
METRIC BOLT TORQUE SPECIFICATIONS
Coarse Thread Fine Thread

Bolt Grade Pitch Foot Newton Pitch Foot Newton
Size No. (mm) Pounds Meter (mm) Pounds Meter
4T 3.6-5.1 4.9-6.9
M6 7T 1.0 6.1-8.3 8.3-11.3 --- --- ---
10T 8.7-11.6 11.8-15.7
4T 9.4-12.3 12.7-16.7 11.2-14.8 15.2-20.1
M8 7T 1.25 16.6-21.0 22.6-28.4 1.0 19.5-25.3 26.5-34.3
10T 21.0-26.8 28.4-36.3 22.4-29.7 30.4-40.2
4T 18.8-24.6 25.5-33.3 21.0-26.8 28.4-36.3
M10 7T 1.5 32.5-41.2 44.1-55.9 1.25 36.2-46.3 49.0-62.8
10T 39.8-51.4 53.9-69.6 42.7-54.2 57.9-73.5
4T 27.5-34.7 37.3-47.1 31.8-40.5 43.1-54.9
M12 7T 1.75 48.5-61.5 65.7-83.4 1.25 55.0-69.4 74.5-94.1
10T 68.0-85.4 92.2-116 73.1-93.3 99.0-127
4T 46.3-59.3 62.8-80.4 51.4-64.4 69.6-87.3
M14 7T 2.0 76.7-96.9 104-131 1.5 86.1-109 117-148
11T 102-129 139-175 108-137 147-186
4T 63.6-81.0 86.3-110 67.3-84.6 91.2-115
M16 7T 2.0 110-136 140-184 1.5 116-142 157-192
11T 152-188 206-255 163-199 221-270
4T 83.9-104 114-141 96.9-120 131-163
M18 7T 2.0 145-174 196-235 1.5 170-206 230-279
11T 203-246 275-333 221-271 299-368
4T 106-132 144-141 127-156 172-211
M20 7T 2.5 177-213 240-289 1.5 203-246 275-333
11T 268-325 363-441 293-358 397-485
10-15
SPECIAL TOOLS
Tool No. Description

NH #FNH01721, CIH #OEM1064 Injector Tester
NH #FNH00120, CIH #CAS2776 Adapter—Compression Tester
NH #FNH01728, CIH #OEM23622 Injector Adapter Set
OEM1074 Compression Test Gauge Assembly
NH #FNH00117, CIH #CAS2778 Port Block Installer
FNH11044 Port Block Installer Pins
NH #FNH11097, CIH #CAS2779 Port Block Remover
FNH11099 Port Block Remover Sleeve (Pair)
NH #FNH00011, CIH #CAS2791 Oil Pressure Test Fitting
Micrometer, Outside 0 -- 25 mm (0 -- 1 inch)
Small Hole Gauge 19 -- 25 mm (3/4 -- 1 inch)
Cylinder Bore Gauge 51 -- 76 mm (2 -- 3 inch)
Cylinder Bore Gauge 25 -- 51 mm (1 -- 2 inch)
10-16
COMPRESSION TEST AND TOOLS

Compression test is performed through the glow plug
ports. The test adapter tool, 1, is equipped with quick
coupler ends for easy installation of the hose and
gauge.
1
The procedures to perform a compression test are as
2
follows:
1. Remove the wire lead from the fuel injection

pump solenoid.
2. Remove the glow plug electrical wire and wire
connector from top of the glow plugs.
1
3. Remove all of the glow plugs.
IMPORTANT: Be sure all the glow plugs are re-
moved before starting the compression tests. 2
4. Install the adapter Tool No. (NH #NH 00120, CIH
#2776) hose and gauge assembly OEM1074, 2,
in each port and crank the engine until pressure
stabilizes. The gauge should read 29.5 bar (427
psi) plus or minus 3.5 bar (50 psi).
NOTE: It may be necessary to remove some injector
fuel lines to install the adapter tool.
NOTE: There should not be more than 3.5 bar (50 psi)
variation between the cylinders. 2
5. When all cylinders have been tested, reinstall the

glow plugs and electrical connections.
10-17
DESCRIPTION OF OPERATION
This chapter describes the engine overhaul and re-
pair procedures of the Models D35, DX35, D40,
DX40, D45 and DX45 tractors. Repair procedures
are essentially the same for all models except as
noted in the repair procedures.
The D35 and DX35 tractors are equipped with three-
cylinder in-line engines. The D40, DX40, D45 and
DX45 tractors are equipped with four-cylinder in-line
engines. They are all four cycle, overhead valve, liq-
uid cooled, diesel engines. The engines are identi- 1
fied by a code, 1, cast into the lower right side of the
cylinder block.
NOTE: Numeric value, 2, under the Engine Code in-

dicates displacement of the engine in liters.
2
20002360
Engine Engine Power

Identification Tractor Model Hp
N843L D35, DX35 35
N844 D40, DX40 40
N844L D45, DX45 45
10-18
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTION

Engine does not develop Clogged air cleaner Inspect and replace air cleaner if
full power necessary
Fuel line obstructed Check for crimped fuel line. Inspect
fuel filter for cleanliness
Improper injection timing Repair/ replace components as
required
Improper nozzle injection pressure Check injection timing
and angle Inspect for proper injection pressure
an angle
Low cylinder compression Check engine compression
Insufficient fuel injection Repair at authorized shop
Improper valve lash adjustment Adjust valves to correct tolerances
Burned, worn or sticking valves Inspect and replace as necessary
Blown head gasket Replace head gasket
Worn or sticking piston rings Overhaul as necessary
Faulty engine stop solenoid Replace stop solenoid
Low oil pressure Engine oil level low Fill to proper level
Wrong grade of oil Replace with correct grade oil
Clogged oil pump filter Change oil and filter
Faulty oil pressure relief valve Replace relief valve
Worn oil pump drive shaft gears
gears, or Inspect oil system and components
components.
broken oil pipe Replace defective components
Excessive main or connecting rod Replace bearings or shaft if
bearing clearances necessary
Oil pump axial clearance not properly Check pump clearance and shim as
set needed to proper tolerance
Engine will not stop Faulty engine stop solenoid Replace the stop solenoid
Faulty starter switch Replace starter switch
Low cylinder compression Burned, worn or sticking valves Replace valves
Bent valve stem Replace valves
Broken or weak valve spring Replace valve spring
Blown cylinder head gasket Replace head gasket
Worn or sticking piston rings Replace piston rings
Scored piston Replace piston
Poor engine idling Improper injection timing Correct the injection timing
Air in injection pump Purge air from the system
Improper governor adjustment Adjust the governor
10-19

Oil pressure warning light Bulb burnt out Replace the bulb
fails to operate
Oil pressure sensor is faulty Replace oil pressure sensor
Warning light circuit faulty Replace warning light circuit
Engine knocks Diluted or thin oil Change engine oil and filter
Insufficient oil supply Check engine oil level
Low oil pressure Inspect lube system for restrictions
Worn crankshaft thrust bearing Replace relief valve
Excessive flywheel runout Replace thrust bearing
Excessive connecting rod or main Replace flywheel
bearing clearance Replace bearings
Seized bearing Replace bearing and affected
component if necessary
Clogged oil passage Clean out oil passages
Bent or twisted connecting rod Replace connecting rod
Crankshaft journals out of round Rework or replace crankshaft
Excessive piston to cylinder bore Replace piston with correct oversized
clearance piston
Excessive piston ring side clearance Replace piston rings
Broken or damaged ring Replace piston ring
Excessive piston pin clearance Replace piston pin or bushing
Seized piston Replace piston and, if necessary,
engine block
Piston pin retainer loose or missing Replace retainer
Improper valve lash adjustment Adjust valve lash to specification
Worn valve lifter Replace valve lifter
Excessive timing gear backlash Replace all timing gears
Excessive oil consumption Engine oil level too high Remove excess oil
Leakage in cylinder head gasket Replace head gasket
Oil loss past the pistons and rings Replace piston rings
Worn, broken, or sticking piston rings Replace piston rings
Cl
Clogged
d return hole
h l off oilil ring
i Unclog
U l return oilil hole
h l and
d replace
l
rings
Worn valves, guides, or seals Replace valves, guides, or seals
Leakage past oil seals and gaskets Replace leaking seals and gaskets
External oil leaks from engine Locate leaks and repair
10-20

Engine overheats Insufficient amount of coolant in the Fill coolant to proper level
radiator
Hose connection leaking or collapsed Tighten hose connection or replace
hose hose
Radiator leakage Locate leak and repair or replace
radiator
Loose, worn, or broken V-belt Adjust V-belt tension or replace belt
Radiator fins bent or clogged Straighten out and clean fins
Radiator cap not sealing Replace radiator cap
Thermostat operating improperly Replace thermostat cap
Insufficient amount of oil Fill to proper level
Water pump operating improperly Replace water pump
Improper valve clearance Adjust valve clearance to specification
Restriction in exhaust system Remove restriction
Improperly installed cylinder head Reinstall head gasket in proper
gasket position
Rust and/or scale clogged water ports Backflush cooling system
Extended engine idling Shutdown engine during extended
idling periods
Temperature gauge fails to Faulty temperature sender Replace temperature switch
reach normal operating
temperature Faulty thermostat Replace thermostat
Faulty temperature gauge Replace temperature gauge
10-21

Engine does not start Faulty starter switch Replace switch
Insufficient charging or complete Check battery and charging system.
discharge of battery
Lack of fuel Fill fuel tank
Air mixed in fuel system Inspect fuel system for tightness
Clogged fuel filter Replace fuel filter
Irregular or faulty fuel supply Replace fuel supply
Glow plug not heating Replace glow plug
Improper lubricating oil viscosity Replace lube oil
Clogged air cleaner Replace air cleaner
Faulty engine stop solenoid Replace solenoid
Burned out fuse Replace fuse
Excessive exhaust smoke Air cleaner dirty or restricted Replace air cleaner
Excessive fuel delivery Adjust fuel delivery
Engine stops while Lack of fuel in fuel tank Fill fuel tank
operating
Clogged fuel filter Replace filter
Air mixed in fuel system Inspect for air leaks
Faulty engine stop solenoid Replace solenoid
Burned out fuse Replace fuse
Undesirable exhaust color Unsuitable fuel Replace fuel
(black or light grey)
Excess injection Adjust injection
Faulty engine component Replace as required
Over loading Decrease load
Clogged air filter Replace filter
Undesirable exhaust smoke Excess engine oil Drain oil to proper oil level
(white or pale)
Improper lubricating oil viscosity Replace oil with specified viscosity
Faulty injection timing Adjust injection timing
10-22
CYLINDER HEAD AND VALVE TRAIN CYLINDER BLOCK ASSEMBLY

COMPONENTS (N843L Engine - D35, DX35)
The cylinder head incorporates the valve assem- The cylinder block assembly contains the pistons,
blies, rocker arms, rocker shaft, push rods, and lift- connecting rods, crankshaft, timing gears, and en-
ers. A swirl chamber located between the injector as- gine oil pump. The crankshaft is supported on four
sembly and the main combustion chamber of the main bearings. The front bearing is positioned in a
cylinders provides improved starting and greater fuel bore in front of the block. The second, third, and
efficiency. Initial combustion starts in the precombus- fourth bearings are split liners located in holders
tion chamber and as the expansion occurs a strong bolted to the block. The camshaft is supported on
swirl pattern is created in the main combustion cham- three ball bearings located in the block.
ber for more complete combustion of the air-fuel mix-
ture. The air intake manifold is separate from the cast
(N844 and N844L Engine - D40, DX40, D45, DX45)
aluminum valve cover on all these engines. The ex-
haust manifold is bolted on the left-hand side of the The cylinder block assembly contains the pistons,
cylinder head on each of the models. Cylinder heads connecting rods, crankshaft, timing gears, and en-
have integral valve guides. Standard size valves only gine oil pump. The crankshaft is supported on five
are used. main bearings. The front bearing is positioned in a
bore in front of the block. The other bearings are split
liners located in holders bolted to the block. The cam-
shaft is supported on four ball bearings located in the
block.
10-23
10044349 10044350
MODEL N843L - D35, DX35
4
10044351
10044352
MODEL N844 and N844L - D40, DX40, D45, DX45
5
10-24
SEPARATING THE TRACTOR AT THE

CLUTCH HOUSING/ENGINE -- 12 X 12
TRANSMISSION
Removal
1. Remove the negative (--) battery cable, 1, and the
positive (+) battery cable, 2, from the battery.
2. Drain all of the hydraulic fluid from the transmis-
1 2
sion and the differential into a suitable container.
3. Disconnect the headlight wire harness plug and
remove the hood from the tractor.
30997558
4. Remove the seat, and the seat base assembly
from the tractor. 6
5. Remove the light bars from the fenders and the
ROPS.
6. If equipped, remove the remote loader control
valve, 1, and the connecting hydraulic tubes from
the right fender.
7. Remove the left and right fenders from the
tractor. 1
30997555
7
8. Remove the left, 1, and right, 2, rear hood side
panels.
9. Disconnect and remove the throttle cable from
the foot throttle control pedal, located on the right 2
deck. 1
10. Remove the left and the right deck from the trac-
tor.
11. Disconnect the throttle cable from the dash
mounted throttle control lever.
10000864
10-25
12. Loosen and remove the two instrument panel re-
taining screws, 1. Remove the instrument panel, 1 1
2, from the dash housing. Disconnect the wiring
connector from the instrument panel.
10035024
9
13. Drive the roll pin, 1, from the lower shuttle shift
shaft, 2. Remove the retaining ring, 3, and the roll
pin, 4, from the lower main shift shaft, 5. Loosen
and remove the retaining bolts, 6, securing the
main shift bracket, 7, and the shuttle shift brack-
et, 8, to the steering column, 9. Remove the shift
shaft assemblies by feeding the control levers
down through the dash housing.
14. Remove the dash housing from the firewall. Dis-
connect the wiring connectors from the dash 6 9
switches. 8 7 6
15. Disconnect the main wiring harness connector.
2
4 5
1
3
10996566
10
16. Remove the firewall support bracket, 1, from the
firewall, 2, and the clutch housing, 3.
2
1
20000908
11
10-26
17. Remove the hydraulic system inlet tube, 1, from
the hydraulic pump, 2.
18. Remove the hydraulic system pressure tube, 3,
from the hydraulic pump, 2, and the diverter 1
valve.
2
3
30997557
12
19. Disconnect the wires, 1, on the starter, 2, and re-
move the starter from the tractor.
30997565 1
13
20. If equipped with FWD, remove the roll pins, 1,
from the front and rear of the FWD driveshaft, 2,
and remove the driveshaft from the tractor.
NOTE: Draining the engine oil and removal of the oil
filter is necessary on the D35 tractor to gain access 2
to several of the buckle-up bolts.
21. Drain the engine oil into a suitable container and 1

remove the oil filter.
1
20000904
14
10-27
22. Remove the fuel supply, 1, and return, 2, lines
from the fuel filter, 3.
23. Drain the fuel tank into a suitable container. 2
10000865
15
24. Attach a chain sling, 1, to the two hoist eyes, 2
1
and 3, on the engine.
10000867
16
25. Attach a suitable hoist, 1, to the chain sling, 2.
NOTE: The hoist is used for supporting the engine
and axle assembly, not for lifting.
26. Roll a floor jack under the tractor from the rear of 1
the tractor, and place under the clutch housing.
Raise the jack enough to support the drive train. 2
10000868
17
10-28
27. Remove the buckle-up bolts, 1, that secure the
engine, 2, to the clutch housing, 3. 1
NOTE: The hoist and/or the floor jack may need to be
raised or lowered to allow the separation of the en-
gine from the clutch housing.
28. Carefully roll the drive train away from the en-
gine, using the floor jack for support.
1
3
2
20000905
18
SEPARATING THE TRACTOR AT THE HST
HOUSING/ENGINE-HST TRANSMISSION
Removal 1
1. Remove the negative (--) battery cable, 1, and the 2
2. Drain all of the hydraulic fluid from the transmis-
sion, differential, and the oil cooler into a suitable
container.
10998231
4. Remove the seat, and the seat track assembly
from the tractor deck. 19
5. Remove the control lever grips, 1, from the con-
trol levers on both sides of the tractor.
6. Remove the left, 2, and the right, 3, control pods
1
from the fenders.
7. Remove the light bars from the fenders and the 3
ROPS.
8. Disconnect and remove the control levers from
the tractor deck and the connecting linkage.
1
10997819/20
20
10-29
9. If equipped, remove the remote, loader control
valve, 1, from the right fender, and the cup holder/ 1
tool box, 2, from the left fender.
tractor.
10998371/8229
21
11. Disconnect and remove the differential lock ped-
al, 1.
10998223
22
12. Disconnect and remove the parking brake
handle, 1.
20046576
23
10-30
panels.
14. Remove the floor mat from the tractor deck.
1 2
10000864
24
15. Drive the roll pin or clip, 1, from the HPL speed
control shaft, 2, and remove the control shaft
from the HPL shaft, 3.
16. Remove the deck from the tractor. 3
19998697
25
17. Loosen and remove the two instrument panel re-
taining screws, 1. Remove the instrument panel, 2
2, from the dash housing, 3. Disconnect the wir- 1
1
ing connector from the instrument panel.
18. Disconnect the throttle cable from the throttle
control lever.
19. Remove the dash housing from the firewall. Dis-
connect the wiring connectors from the dash
switches.
3
20. Disconnect the two main wiring harness
connectors.
20045713
26
10-31
firewall, 2, and the HST housing, 3.
3 2
10000863
27
23. Remove the hydraulic system pressure tube, 3,
from the hydraulic pump, 2, and the diverter
valve. 1 2
3
30997557
28
24. Remove the HST oil cooler tube, 1, and the HST
pressure tube, 2, from the tractor. 1
30996397
29
10-32
25. Disconnect the wires, 1, on the starter, 2, and re-
move the starter from the tractor.
30997565 1
30
26. Remove the two FWD, driveshaft, front and rear,
retaining bolts, (one roll pin on standard FWD 1
axle), and remove the driveshaft from the tractor.
30996382
31
27. Use a floor jack, 1, to raise the front of the tractor
and place wood blocks, 2, between the axle, 3,
and the frame, 4. Lower the jack.
1 4 2
10000866 3
32
10-33
28. Remove the cotter pin, 1, and the castle nut, 2,
from the support bar, 3, at the rear mounting
bracket, 4.
29. Use a brass drift and a hammer to drive the sup-
port bar, 3, stud out of the mounting bracket, 4.
filter is necessary on the DX35 tractor to gain access
1
30. Drain the engine oil into a suitable container and
3
remove the oil filter. 2
20000902 4
33
2
10000865
34
1
10000867
35
10-34
10000868
36
35. Roll a floor jack under the tractor from the rear of
the tractor, and place under the HST housing.
Raise the jack enough to support the drive train.
36. Remove the buckle-up bolts that secure the en-
gine to the HST housing.
raised or lowered to allow the separation of the en-
gine from the HST housing.
10000869
37
37. Carefully roll the drive train away from the en-
gine, using the floor jack for support.

ENGINE/FRAME
1. Use jack stands under the frame rails to support
the front frame/engine assembly.
WARNING
Make sure the front frame/engine assembly is se-
curely supported before removing the chain
sling from the engine.
10000870
2. Remove the chain sling from the two hoist eyes 38

on the engine.
10-35
3. Drain the hydraulic fluid from the power steering
reservoir, 1, into a suitable container. Remove
the reservoir, 1, from the firewall, 2.
4. Remove the power steering lines, 3, from the
power steering control motor, 4, the frame, 5, and
the power steering pump, 6.
2
1
4
3
5
6
20002368
39
5. Remove the air cleaner assembly, 1, from the

firewall, 2. 1
20002366
40
10-36
6. Remove the muffler guard, 1, from the tractor.
1
3
2
30996394
41
7. Remove the muffler, 1, and the exhaust pipe, 2,
from the tractor. 1
8. Drain the coolant from the radiator into a suitable
container.
9. Remove the top and the bottom radiator hoses.
10. Remove the radiator and the oil cooler (if
equipped) from the tractor.
20002367
42
11. Remove the firewall, 1, and the air cleaner
mounting bracket, 2, from the engine.
12. Attach a chain sling to the two hoist eyes on the
engine.
1
13. Attach a suitable hoist to the chain sling, and
raise the hoist enough to support the engine.
20002370
43
10-37
14. Loosen and remove the engine mounting bolts,
1, on both sides of the frame. 1
15. Carefully lift the engine from the frame.
16. Attach the engine to a suitable engine stand.
17. With the engine securely attached to the engine
stand, remove the chain sling from the two en-
gine hoist eyes.
20002365
44
Installation
1. Attach a chain sling to the two hoist eyes on the
engine.
2. Attach a suitable hoist to the chain sling and raise
the hoist enough to support the engine.
3. Remove the engine from the engine stand.
4. Using the hoist, position the engine in the frame,
aligning the mounting holes in the frame with the
mounting holes in the engine.
5. Install the engine mounting bolts, 1, on both sides

of the frame. Tighten the mounting bolts to 1
139-175 N⋅m (102 - 129 ft. lbs.).
6. With the engine securely installed into the frame,
remove the chain sling from the two engine hoist
eyes.
20002365
45
10-38
7. Install the firewall, 1, and the air cleaner mount-
ing bracket, 2, onto the engine.
8. Install the radiator and the oil cooler (if equipped)
onto the tractor frame.
1
9. Install the top and bottom radiator hoses.
10. Fill the radiator with new coolant to the proper
level.
2
20002370
46
11. Install the muffler, 1, onto the exhaust manifold,
and attach the exhaust pipe, 2, onto the muffler. 1
20002367
47
10-39
12. Install the muffler guard, 1, on the tractor.
30996394
48
13. Install the air cleaner assembly, 1, on the firewall,
2, and connect the air inlet hose to the air inlet 1
manifold pipe.
20002366
49
10-40
14. Connect the power steering tubes, 3, to the pow-
er steering control motor, 4, the frame, 5, the
power steering reservoir, 1, and the power steer-
ing pump, 6.
15. Install the power steering fluid reservoir, 1, to the
firewall, 2. Connect the hose from the reservoir,
1, to the power steering pump, 6. Fill the reservoir
to the proper level with Hy-Tran Ultra hydraulic
fluid.
2
1
4
3
5
6
20002368
50
10-41
ATTACHING THE 12 X 12 TRANSMISSION 1

TO THE ENGINE
WARNING
Do not use the buckle-up bolts to draw the drive
2
train together with the engine. Severe damage to
the drive train may result.
1. Attach a chain sling, 1, to the two hoist eyes, 2 3

10000867
51
3. Carefully roll the drive train into alignment with
the engine. Align the splines on the 12 x 12 input
shaft with the clutch and the engine flywheel. Ro-
tate the engine fan to align the input shaft and the 1
clutch/flywheel. The floor jack or the hoist may
need to be raised or lowered to make alignment 2
possible.
10000868
52
4. Connect the clutch housing, 3, to the engine, 2, and
install the buckle-up bolts, 1. Tighten the buckle-up 1
bolts in a criss-cross pattern. Torque the M10 bolts
and nuts to 43.4-55.6 N⋅m (32-41 ft.-lbs.). Torque
the two M12 bolts to 81 N⋅m (60 ft.-lbs.).
1
3
2
20000905
53
10-42
5. Remove the chain hoist, 1, and the sling, 2, from
the engine hoist eyes. Remove the floor jack from
the tractor.
10000868
54
6. Connect the fuel supply line, 1, to the fuel shutoff/
filter, 3, and connect the fuel tank vent line, 2, to
the tee fitting.
3
2
10000865
55
7. Attach the firewall support, 1, to the firewall, 2,
and the clutch housing, 3. Secure with the retain-
ing bolts.
2
1
20000908
56
10-43
8. If equipped, Install the FWD driveshaft, 2, and se-
cure with the two roll pins, 1.
1
20000904
57
9. Install the starter, 2, onto the engine, and secure
with the retaining nuts. Connect the wires, 1, to
the starter, 2.
2
30997565 1
58
10. Install the hydraulic system pressure tube, 3, on
the hydraulic pump, 2, and the diverter valve.
11. Install the hydraulic system inlet tube, 1, onto the
hydraulic pump, 2. 1
12. Connect the main wiring harness connector. 2
13. Install the left and right deck onto the tractor.
14. Connect the throttle cable to the foot throttle con-
trol lever located on the right deck.
15. Install the left and right fenders on the tractor.
16. Install the seat and the seat base on the tractor.
3
30997557
Connect the seat safety start switch.
59
17. Install the light bars onto the fenders and the
ROPS.
10-44
18. If equipped, install the remote loader control
valve, 1, on the right fender. Connect the hydrau-
lic tubes.
19. Install the dash housing onto the tractor.
1
20. Connect the wiring connectors to the dash hous-
ing switches.
21. Connect the throttle cable to the dash mounted
throttle control lever.
30997555
60
22. Connect the instrument panel wiring plug to the
instrument panel. Install the instrument panel, 2, 1 1
into the dash housing and secure with two
screws, 1.
10035024
61
23. Install the main shift and the shuttle shift control
levers through the dash housing, and connect
the main shift bracket, 7, and the shuttle shift
bracket, 8, to the steering column, 9, with the re-
taining bolts, 6. Connect the lower main shift
shaft, 5, and shuttle shift shaft, 2 to the transmis-
sion shafts with the roll pins, 4 and 1, and retain-
ing ring, 3.
24. Install the hood on the tractor and connect the
headlight wiring connector. 6 9
8 7 6
2
4 5
1
3
10996566
62
10-45
25. Install the left, 1, and right, 2, rear hood side
panels. 2
26. Fill the hydraulic reservoir with Hy-Tran Ultra Hy- 1
draulic Fluid, to the proper level.
NOTE: The following step is required on the D35
tractor.
27. If the engine oil was drained, and the oil filter was
removed during disassembly, install a new oil fil-
ter on the engine, and fill the engine with the rec-
ommended oil to the proper level.
10000864
63
28. Connect the positive (+), 2, and the negative (--),
1, battery cables to the battery.
29. Check the fluid levels and start the tractor. Check
for leaks and proper operation of all systems.
30. Make any adjustments necessary for proper op-
eration of the tractor.
1 2
30997558
64
ATTACHING THE HST TO THE ENGINE 1
WARNING
WARNING: Do not use the buckle-up bolts to
draw the HST together with the engine. Severe
damage to the drive train may result. 2

and 3, on the engine. 3
10000867
65
10-46
10000868
66
the engine. Align the splines on the HST input
shaft with the coupler on the engine flywheel. Ro-
tate the engine fan to align the input shaft and the
coupler. The floor jack or the hoist may need to
be raised or lowered to make alignment possible.
4. Connect the HST housing to the engine and
install the buckle-up bolts and nuts. Tighten the
buckle-up bolts and nuts in a criss-cross pattern.
Torque the M10 bolts and nuts to 43.4-55.6 N⋅m
(32-41 ft.-lbs.). Torque the two M12 bolts to 81 N⋅m
(60 ft.-lbs.).
10000869
67
the tractor.
10000868
68
10-47
6. Connect the fuel supply line, 1, to the fuel shutoff/
filter, 3, and connect the fuel tank vent line, 2, to
the tee fitting.
3
2
10000865
69
7. Attach the firewall support, 1, to the HST hous-
ing, 3, and the firewall, 2. Secure with the retain-
ing bolts.
3 2
10000863
70
8. Install the FWD driveshaft, 2, and secure with the
retaining bolts, 1, (one roll pin on standard FWD 1 2
axle). Torque the retaining bolts, 1, to 20 N⋅m (15
ft. lbs.).
30996382
71
10-48
9. Install the support bar stud, 3, into the mount, 4,
and secure with the castle nut, 2. Torque the
castle nut to 135.6-169.5 N⋅m (100-125 ft.-lbs.).
Install a new cotter pin, 1, through the castle nut,
2, and the support bar stud, 3.
3 1
4 2
20000902
72
10. Place a floor jack, 1, under the front of the tractor,
and raise the tractor. Remove the wood blocks,
2, from between the front axle, 3, and the
frame, 4.
1 4 2
10000866 3
73
the starter, 2.
2
30997565 1
74
10-49
12. Install the HST oil cooler tube, 1, and the HST
pressure tube, 2, onto the tractor. 1
30996397
75
14. Install the hydraulic system inlet tube, 1, onto the
hydraulic pump, 2. 1
15. Connect the two main wiring harness connec- 2
tors.
16. Install the tractor deck onto the tractor.
3
30997557
76
17. Install and connect the differential lock pedal, 1.
NOTE: For ease of control lever assembly, raise the
tractor on a floor jack and remove the rear wheels.
This is not required but will ease assembly.
1
10998223
77
10-50
18. Install and connect the parking brake lever, 1.
20046576
78
19. Install the HPL speed control shaft, 2, onto the
HPL shaft, 3.
20. Install and connect the control levers on the left
and right side of the tractor deck. 3
19998697
79
10-51
22. Install the left, 2, and right, 3, control pods on the
fenders. Install the control lever grips, 1, on the
control levers. 1
23. Install the floor mat onto the tractor deck.
24. Install the seat and the seat track on the tractor. 3
ROPS.
1
10997819/20
80
26. Install the cup holder/tool box, 2, on the left fend-
er, if equipped. 1
27. Install the remote, loader control valve, 1, on the
right fender, if equipped. Connect the hydraulic
tubes.
29. Connect the wiring plugs to the dash housing
switches.
10998371/8229
81
10-52
instrument panel. Install the instrument panel, 2,
2
into the dash housing, 3, and secure with two 1 1
screws, 1.
31. Install the hood on the tractor.
3
20045713
82
32. Install the left, 1, and right, 2, rear hood side pan-
els. 2
33. If removed, install the left and right rear wheels. 1
34. Fill the hydraulic reservoir with Hy-Tran Ultra Hy-
draulic Fluid, to the proper level.
NOTE: The following step is required on the DX35
tractor.
removed during disassembly, install a new oil fil-
ter on the engine, and fill the engine with the rec-
ommended oil to the proper level. 10000864
83
37. Check the fluid levels and start the tractor. Check 1
38. Make any adjustments necessary for proper op- 2
eration of the tractor.
10998231
84
10-53
OVERHAUL
ENGINE
NOTE: Some procedures discussed in this chapter
are shown with the engine in the tractor. Many of the
procedures can be done with the engine in or out of
the tractor.
FUEL INJECTOR AND GLOW PLUG

5 4 4
Removal
1. Clean all dirt and oil from the injectors and sur-
rounding areas.
2. Disconnect the fuel lines, 1, from the injectors
and cap all openings. 3
3. Remove the injector fuel leak-off line, 3. 2
4. Remove the injector assemblies, 2.
1
5. Remove the glow plug bus connector, 5, and re-
move the glow plugs, 4.
85
OIL PRESSURE SWITCH
Remove the oil pressure switch, 1. 1
86
TEMPERATURE SENDING SWITCH AND
2 1
ALTERNATOR
Removal
1. Remove the temperature sending switch, 1, from 4
the front of the cylinder head.
2. Loosen the alternator mounting bolts, 2, and re-
move the V-belt, 3, from the drive pulley.
2
3. Disconnect the alternator wires from the back of
alternator, 4.
4. Remove the alternator mounting bolts, 2, and re- 3
move the alternator.
87
10-54
FAN, WATER PUMP AND EXTERNAL OIL

TUBE
Removal
1. Remove the fan and water pump assembly. See
“Water Pump Removal” discussed later in this
section.
1
2. Remove the external oil transfer tube banjo bolt,
1, from the front of the cylinder head.
19988040
88
AIR INLET MANIFOLD
3 2
Removal
1. Remove the retaining bolts, 1, cap nuts, 2, and
seal washers, 3. 1
4
2. Remove the air inlet manifold, 4, and gasket, 5.
5
10044353
89
10-55
ROCKER ARM SHAFT AND SUPPORT

2 3 2
BRACKET 1
Removal
1. Remove the bolts, 2, and nuts, 3.
2. Remove the rocker arm shaft and support
bracket as an assembly, 1.
NOTE: Alternately loosen the rocker support bolts a
turn at a time to prevent distorting the rocker shaft.
10044354
90
Op. 10 101
1 2
CYLINDER HEAD
Removal
1. Remove the valve stem caps, 1, and push
rods, 2.
NOTE: Keep all valve components in separately
marked containers for re-assembly in their original
location.
2. To remove the cylinder head, remove the cylinder 3

head bolts, 3, by alternately loosening a half turn
at a time to prevent warping the head. 91
10-56
VALVE TAPPET
Removal
Remove the valve tappets, 1, from the machined
bore in the cylinder block.
92
FUEL SHUTOFF SOLENOID
Removal
Remove the wire connector and unscrew the fuel
shutoff solenoid, 1.
93
ENGINE TIMING GEAR COVER, TIMING
GEARS AND CAM SHAFT 3
Timing Gear Cover Removal 1
1. Drain the engine crankcase oil.
2. Remove the crankshaft pulley. 2
2
3. Loosen the four injection pump mounting bolts,
2, and raise the injection pump, 3, enough to re-
move the spring pin, 1, and separate the gover-
nor link from the control rack. Remove the injec-
tion pump.
94
10-57
NOTE: Insert a small dowel, 1, through the fuel shut-
off solenoid hole and slide the control rack, 2, in to al-
low enough clearance to the cylinder block, for the 1 2
pump to be removed.
20002371
95
4. Remove the power steering pump reservoir tank
dipstick-filler cap, 1. 1
5. Remove the reservoir drain plug, 2, and drain the
hydraulic fluid out of the reservoir tank, 3, into a
suitable container.
30996392 2
96
6. Loosen the hose clamp, 1, on the suction hose,
2, and remove the suction hose from the steering
pump, 3.
2
7. Remove the pressure tube, 4, from the bottom of 1

the steering pump.
3
30996355 4
97
10-58
8. Remove the through bolts and nuts, 1, and re-
move the steering pump from the front cover.
Cap the lines and pump openings.
NOTE: Two of the power steering pump retaining
bolts are not shown.
30996393
98
9. Install and tighten two nuts, 1, against each other,
onto the retaining studs, 2. Remove the studs, 2,
and the hydraulic pump, 3.
3
20002372 2
99
10-59
10. Remove the retaining nut, 1. Pull crankshaft
pulley, 2, off of crankshaft, 3. 2
1
3
20002373
100
11. Remove the retaining bolts, 1, and lift the cover,
2, off the locating dowels. 1
101
Op. 10 106
TIMING GEARS AND CAMSHAFT

Removal 1
1. Remove retaining ring, 1, and remove the idler
gear, 3, and oil pump assembly, 2.
102
10-60
2. Remove the two bolts, 1, securing the keeper
plate, 3. One must be accessed using the access
hole, 2, in the cam gear. 2
3. Slide the camshaft and gear out of the camshaft 3
bore.
10044355 1
103
Op. 10 102
OIL SUMP
Removal
1. Remove the oil sump retainer bolts, 1.
2. Remove the oil sump and discard gasket.
104
OIL SUCTION PIPE AND STRAINER
2
Removal
1. Remove the two retaining bolts, 1.
3
2. Remove the oil strainer, 2, and rotate the oil suc-
tion pipe, 3, out of its bore. Remove from the front
side of the block.
10044356
105
10-61
Op. 10 110
BALANCER ASSEMBLY
(4 Cylinder Engines Only)
Removal
1. Remove the banjo bolts, 1, and the oil transfer 6
pipe, 2.
2. Loosen and remove the balancer retaining 4
bolts, 3.
NOTE: Observe the quantity and thickness of the 4
shims, 4, (if used) for re-installation upon assembly.
3. Remove the balancer assembly, 5, from the en-

gine block, 6.
5
2
1
20002374
106
Op. 10 105
CONNECTING RODS, BEARINGS AND 1 2

PISTONS, RINGS
Removal
1. Remove the two bolts, 1, retaining the connect-
ing rod caps, 2.
2. Remove the connecting rod caps and lower half
of connecting rod bearing.
3. If necessary, remove any ridge from the top of the
cylinder bores using a suitable ridge reamer.
107
4. Push the piston and connecting rod out of the cyl-
inder block.
5. Replace the connecting rod cap to the piston as-
sembly it was removed from. Keep together in
cylinder sequence.
108
10-62
Op. 10 103
FLYWHEEL
Removal
1. Loosen the flywheel retaining bolts.
2. Using a brass drift and hammer, tap the end of
the crankshaft, 1, to loosen the flywheel, 2, from
the shaft.
2
1
109
BACKPLATE AND OIL SEAL
Removal
1. Remove the backplate retaining bolts and re-
move the backplate.
2. Remove the rear oil seal, 1.
110
CRANKSHAFT AND MAIN BEARINGS
Removal
1. Remove the crankshaft bearing holder retaining
bolts, 1.
2. Slide the crankshaft and main bearing assembly 1
through the rear of the engine.
111
10-63
Op. 10 101
CYLINDER HEAD
Disassembly
1. Clean the cylinder head and remove any carbon 2 4
deposits from around the valve heads.
2. Use a valve spring compressor and remove the 1 3
valve spring retainer locks, 1, spring, 2, and
spring retainer, 3, from each valve, 4.
3. Remove the valves and place the valve compo-
nents together in separately marked containers
for reassembly in their original position.
112
Inspection and Repair
1. Clean all carbon deposits from the combustion
chamber and valve ports using a wire brush and
scraper.
2. Clean all dirt and residue from the gasket surface
using care not to scratch or nick the machined
surface.
3. Clean the cylinder head in solvent and air dry.
4. Inspect the head for cracks or damage in the fol-
lowing areas: 1
2
-- Valve ports
-- Valve seats, 2
-- Prechamber, 3
-- External cracks in the water jackets, 1
5. Inspect the gasket surfaces for scratches or
nicks, which could cause leakage.
6. Examine the core hole plugs for rust or signs of
leakage. If a plug shows signs of damaging rust
or leakage, replace all plugs in the head. 3
7. Inspect the prechamber for carbon deposits and 113
looseness. Remove any carbon deposits found.
If prechamber is found to be loose, cylinder head
may be warped.
10-64
8. Use a straight edge and a feeler gauge and
check the cylinder head for warp lengthwise,
crosswise, and diagonally.
114
VALVE SEATS 1
Examine the valve seats and surface the seat if dam-
aged. Valve seat grinding requires that the seat be
ground to the correct width and properly positioned.
A valve that extends too deep into the combustion
area will result in valve burning. If the valve is re-
cessed too deep into the head it will cause a rapid 2
build-up of carbon deposits.
3
115
1. Correct Valve Seat Width and Location
2. Correct Valve Head Margin N843 0.7 - 1.0 mm
(0.027 - 0.039″)
3. 45° Valve Seat Angle
1. Check the seat for surface defects. Use a 45° 150° 3

stone if necessary to reface. Grind away only
enough material to provide a smooth even seat. 90° 1
2. Check the seat width. If necessary, use a 15°
stone to lower the seat contact point and use a 30° 2
75° stone to raise the seat contact point.
0.020 IN.
NOTE: Refacing the seat should always be coordi- (0.5 MM)
nated with refacing of the valve to ensure a compres- MIN.
sion tight fit.
116
1. Seat angle - 45° Stone
2. Lower Seat Location - 15° Stone
3. Raise Seat Location - 75° Stone
10-65
VALVES
Clean all deposits from the valves using a soft wire
brush. Inspect the condition of the valves and discard
any that are badly burned, cracked, or bent.
2
6 5
4
1 3
117
1. Using a micrometer, measure the valve stem at
points “A,” “B,” and “C.” A B C
A B C
118
1. 45° Angle Seat
2. Minimum Valve Margin
2. If inspection indicates that the valve may be re-

used, the valve should be ground.
3. After grinding the valve and seat, check to ensure
the seat contacts the center of the valve face. Us-
1
ing Prussian Blue, lightly coat the valve seat,
2
place the valve in position and rotate the valve
slightly while holding a light pressure against the
valve. If the blue is transferred to the center of the
valve face, the contact is correct.
119
10-66
4. If Prussian Blue is not available, mark the valve
face or seat, 1, with a soft lead pencil. Rotate the
valve slightly in the seat. The penciled lines will
be broken at the seat contact area.
120
VALVE GUIDES 1
Thoroughly clean the valve guides before attempting
to check internal wear.
1. Using a telescoping gauge and micrometer,

measure the valve guide bore at the top and bot-
tom wear points, 1.
1
121
2. Determine the valve stem to valve guide clear-
ance, 1, by subtracting the valve stem diameter
from the valve guide diameter. Replace valves if
the clearance, 1, is more than 0.2 mm (0.008″),
intake valves, or 0.25 mm (0.010″), exhaust
valves.
3. Replace the cylinder head if excessive clearance
is determined and the valves have met all speci- 1
fied measurement requirements. See “Specifica-
tions,” discussed earlier in this section.
122
10-67
VALVE SPRINGS
1. Place the valve springs on a flat surface. Mea-
sure the free length of the spring and square-
ness. Replace springs that do not meet the fol-
lowing specifications (all models):
Max. Out of Square Min. Free-Length

2.0 mm (0.079″) 33.5 mm (1.319″)
2. Place the springs in a suitable spring load tester

and measure the spring load rating. Replace
springs that do not meet the following specifica-
tions (all models):
123
Standard Maximum
8.1 kg (17.86 lbs.) 7 kg (15.43 lbs.)
at 30.4 mm (1.197″) at 30.4 mm (1.197″)
ROCKER ARMS
1. Thread an 8 mm bolt, 1, into the rear end of the
rocker shaft, 2, and slowly withdraw the rocker
shaft while at the same time removing the rocker
arms and springs.
2. Inspect the rocker arms, 3, and shaft for wear or 2
damage. Check the adjusting screws for dam-
aged threads or excessive wear.
3. Check the valve stem contact area for pitting or
excessive wear. Slight wear patterns may be re-
moved using a fine grit oil stone.
NOTE: The rocker shaft housing must be removed
from the cylinder head, before rocker shaft can be 4
removed from housing. Housing mounting bolts
retain rocker shaft. 1
10044357
124
1. 8 mm Bolt
2. Rocker Arm Shaft
3. Rocker Arm
4. Shims
10-68
4. Using an outside micrometer, measure the wear
points, 1, on the rocker shaft. Replace the rocker
shaft if the wear at any point exceeds 0.2mm
(0.008″).
1
NOTE: Lube holes, one set on bottom of rocker shaft

at 170° from the oil pressure check hole.
10044358
125
measure the inside of the rocker arm. Replace
rocker arms having a bore diameter exceeding
14.87 mm (0.584″). Replace the rocker shaft
and/or rocker arm if the rocker arm to shaft clear-
ance exceeds 0.2 mm (0.008″).
NOTE: Rocker arms have no bushings and only one
lube hole.
20002375
126
PUSH RODS
1. Check the push rods for straightness by rolling on
a flat surface. Replace rods that are bent.
2. Inspect the ends of the push rods for excessive
wear. If any push rod is worn, the corresponding
lifter and rocker arm should also be inspected for
excessive wear.
CYLINDER HEAD
Assembly
1. Insert each valve in the guide from which it was re-
moved and lightly lap the valve to be sure of an
even seat around the valve face. Remove the
valve and remove all traces of lapping compound.
2. Install new intake valve seals on the valve guides
using a suitable driver.
3. Using a spring compressor, assemble the
valves, springs, retainers, and keepers.
10-69
CYLINDER BLOCK
1. Inspect the cylinder block top face for cracks,
damage, and warping in the same way as for the
cylinder head. Replace the cylinder block if warp
is greater than 0.12 mm (0.005″).
2. Visually inspect the cylinder bore. There should
be no scoring, rust, or corrosion.
3. Using a telescoping gauge in line with the crank-
shaft, measure the inside diameter of the top of
the bore (approximately 15 mm [0.59″] below the
top of the block) on all models.
4. Repeat this measurement at right angles to the
crankshaft at the same distance.
5. In line with the crankshaft at the bottom of the
bore, measure (approximately 117 mm [4.6″]
Model N844, and 127 mm [5″] Model N843 and
N844L) from the top of the cylinder.
127
6. Repeat this measurement at right angles to the
crankshaft at the same distance.
7. If any of the measurements taken indicate worn
or damaged cylinder bores, replace engine block
with a long block assembly.
NOTE: If the cylinder bore measures 84.2 mm
(3.315″) replace the block.
Op. 10 105
PISTONS
Disassembly and Inspection
1. Remove the piston rings using a piston ring tool.
20002376
128
10-70
2. Remove the wrist pin, 1, retaining rings and drive
the wrist pin out of the piston using pin remover, 2.
1
129
3. Wash the pistons and connecting rods in a suit-
able solvent and air dry.
4. Using a groove cleaner, remove the carbon de-
posits from the ring grooves. Be careful to avoid
cutting any metal from either side or the bottom
of the grooves.
130
5. Inspect the piston ring lands for excessive wear.
Use a new ring, 1, and feeler gauge, 2, to check
the ring side clearance. Replace pistons having
a ring side clearance exceeding the following di- 1
mensions:
2
Compression Ring Oil Control Ring
0.25 mm (0.010″) 0.25 mm (0.010″)
131
10-71
6. Using a micrometer, check the piston diameter at
90 degrees from the wrist pin bore. Replace pis-
tons that are worn to less than the following di-
mensions:
Model Wear Limit

All 83.9 mm (3.3″)
132
7. Using a telescoping gauge and a micrometer,
measure the piston pin bore and the wrist pin di-
ameter. Replace piston and/or wrist pins that ex-
ceed the following limits:
Bore Diameter: 28.0 mm (1.102″)
Pin Diameter: 27.98 mm (1.101″)
Clearance: 0.02 mm (0.0008″)
NOTE: In some instances the wrist pin diameter may
be equal to or slightly larger than the wrist pin bore.
This interference fit is normal.
133
10-72
PISTON RINGS
1. Position the piston rings, 1, one at a time, in the
cylinder to the lowest point of travel. Use an in-
verted piston to square the ring in the bore. 2
2. With a feeler gauge, 2, measure the ring gap. 1
The ring is shown at the top of its travel for clarity.
3. Replace worn rings with end gap clearance in ex-
cess of 1.0 mm (0.039″).
134
CONNECTING RODS
1
1. Check the connecting rods for damage and align- 2
ment. Place each rod in an alignment fixture to
check for bent or twisted condition.
2. Straighten or replace rods that are bent or twisted
more than the following dimensions: 3
Max. Bend: 0.15 mm (0.0059″)
per 100 mm (3.94″)
Twist: 0.2 mm (0.0078″)
per 100 mm (3.94″) 2 BENT ROD
1
TWISTED ROD
135
1. Alignment Fixture
2. Gauge
3. Connecting Rod
3. Using a telescoping gauge and a micrometer,

1
measure the inside diameter of the connecting
rod wrist pin bushing.
4. Replace bushings measuring more than the
following:
Model Max. Inside Diameter

All Models 28.021 mm (1.103″) 3
2
136
10-73
5. Remove and install the connecting rod wrist pin
bushings using a suitable driver and press a new
bushing into the rod bore.
6. Ream and hone the bushing to the following fin-
ish size. 1
Pin to Bushing Clearance 2

3
Std. Max.
0.010 - 0.025 mm 0.08 mm
(0.00039″ - 0.00098″) (0.0031″)
137
1. Hole Gauge
2. Micrometer
3. Connecting Rod
7. When installing a new piston pin bushing, use the

hole in the rod and drill a lube hole in the new
bushing.
138
1. Press
2. Connecting Rod
3. Bushing Driver
10-74
8. Install the connecting rod on the crankshaft and
measure the play in shaft direction. If the play is
more than 0.7 mm (0.028″) replace the connect-
ing rod. 1
139
1. Side Clearance Check 0.7 mm (0.028″) Max.
CONNECTING ROD BEARING

Clearance Check
2
1
1. Remove oil or foreign matter from the bearing
and crankshaft.
2. Cut a piece of plastigauge, 1, to the same width
as the bearing. Place it on the crankshaft. Avoid
the oil hole.
3. Install the rod cap and torque to 49.0 - 53.9 N⋅m
(36.2 - 39.8 ft.-lbs.).
4. Remove the rod cap and measure the width of START FLATTENED
the flattened plastigauge using the plastigauge
scale. 140
5. The width of the widest flattened plastigauge is 1. Plastigauge
the minimum clearance and the width of the nar- 2. Bearing Clearing Check
rowest plastigauge is the greatest clearance. Se-
lect the proper size bearing liners to obtain the
correct clearance. See “Specifications” earlier in
this section.
10-75
PISTONS, RINGS AND CONNECTING ROD

Assembly
2
1. Assemble the pistons and connecting rods with

the matching marks, 1, on the rods on the same
side as the trade name “SHIBAURA,” 2, em-
bossed on the inside of the piston skirt. Install the
piston pin, and retaining rings.
141
2. Using a suitable ring expander tool, install the
piston rings positioning the ring gaps at approxi-
mately 120 degrees from each other. Install the
third (oil ring) first as follows:
Put the expander ring, 1, into position in its
groove.
Fit the outer oil ring, 2, into position in its groove,
while making sure the outer oil ring gap is
diametrically opposite to the joint on the 1
expander ring, 1.
2
10044359
142
10-76
Op. 10 103
CRANKSHAFT -- MAIN BEARING AND

THRUST WASHER
Removal and Inspection 1
1. Remove the two retaining bolts from the bearing
holders, 1.
2. Remove the bearing holders and bearing liners, 2. 2
3. Position a piece of plastigauge across the full
width of the bearing liners.
4. Install the bearing holder and tighten the bolts to 4
49.0 - 53.9 N⋅m (36.2 - 39.8 ft.-lbs.).
NOTE: Do not permit the bearing holder to rotate,
even the slightest amount.
5. Remove the bearing holders and measure the 3
width of the flattened plastigauge using the
gauge printed on the plastigauge package.
6. Replace components or grind the crankshaft to
the next undersize bearing as required to obtain
the correct clearance. See “Specifications” earli-
er in this section.
7. Check the thrust washer for wear, poor contact,
burning, or other defects. Using a micrometer
measure the washer thickness. If washer thick- D35, DX35
ness is not within allowable limits or found to be 143
defective, the washers must be replaced. 1. Holder
Standard Thickness: 2.95 mm-3.0 mm 2. Upper Main Liner (with oil groove)
(0.116″-0.118″) 3. Thrust Bearing
4. Lower Main Liner (no oil groove)
Allowable Limit: 2.8 mm (0.11″)
20044366 D40, DX40, D45, DX45
144
10-77
CRANKSHAFT
1. Inspect the crankshaft gear teeth for wear or 1 2
damage and replace if necessary.
1 2
A
B B
145
A. Taper Readings: 1 vs. 2
B. Out-of-Round Readings: A vs. B
2. Using a dial indicator, measure the crankshaft

journals for size, runout, and tapper.
2 2
3. The amount of tapper in a journal is the difference
in the measurements taken at points 1 and 2 on 1 1
a journal.
4. The amount of out-of-round in a journal is the dif-
ference in the measurements taken at 90° points
on the journal.
NOTE: The smallest reading taken at any one of
the readings indicates the size of the journal.
See “Specifications” for wear limits and repair
recommendations.
146
NOTE: Undersize bearings are available in 0.25 -
0.50 mm (0.010 - 0.020″) for both main and crankpin
journals. See “Specifications” for wear limits and
bearing usage.
5. Mount the crankshaft in a set of V-blocks

and measure the amount of runout using a dial
indicator.
6. Straighten or replace crankshafts that exceed
runout specifications. See “Specifications,” dis-
cussed earlier in this section.
10-78
BEARING (BUSHING)
1. Check the bearing (bushing) for peeling, melting,
seizure, or poor contact.
measure the oil clearance between the bearing
(bushing) and the crankshaft journal. 3
1 2 4
3. Measure the inside diameters at positions 1 and
2. At each position, measure in both directions 3
and 4. The oil clearance can be obtained by sub-
tracting this value from the maximum crankshaft
journal diameter.
4. If the oil clearance exceeds 0.2 mm (0.0078″) re-
place the bearing (bushing) or grind the crank- 147
shaft journal. In this case, use an undersized
bearing (bushing).
Replacement CYLINDER
1. Remove the bearing from the front of the cylinder CLINCH BLOCK
15
block housing using a bushing driving tool to pre- 12.5
vent damage.
2. Inspect the bushing housing for marks,
scratches, or damage.
FRONT SIDE
3. The bushing should be smoothly pressed into the
correct depth by using a bushing driving tool,
aligning the oil hole, and direction of bushing.
• Press the bushing into the cylinder block
from the engine front side. 1
ALIGN
NOTE: Do not press the bushing into the cylinder
block from the opposite side. 148
NOTE: The correct pressing side is chamfered, etc.,

to allow smooth operation.
• Lubricate the outer surface of the bushing.

• Align the oil hole, 1, of the housing and
bushing.
• Press the bushing into the housing until the
correct depth by using a bushing driving tool.
4. Confirm the housing and bushing oil holes are in

alignment.
10-79
MAIN BEARING
1 1 1
Assembly
D35, DX35
1. Install the bearing holders, 1, along with their lin-
ers. The rear bearing is also assembled along
with the thrust bearing halves, one located on
each side of the bearing. Be sure the bearing
holders are correctly positioned on the shaft with
the chamfered edge facing forward.
2. Torque the bearing holder retaining bolts to 49.0
- 53.9 N⋅m (36.2 - 39.8 ft.-lbs.). 2 3 D35, DX35
149
1. Bearing Holder
2. Thrust Bearing
3. Holder Chamfer (stepped)
D40, DX40, D45, DX45

1
1. Install the bearing holders, 1, along with their lin-
ers. The rear bearing is also assembled along 3
with the thrust bearing halves, one located on
4 4
each side of the bearing. Be sure the bearing
holders are correctly positioned on the shaft with
the chamfered edge facing forward.
2. Torque the bearing holder retaining bolts to 49.0
- 53.9 N⋅m (36.2 - 39.8 ft.-lbs.). 2
20044367 D40, DX40, D45, DX45

150
1. Bearing Holders
2. Thrust Bearing
3. Lead Chamfer (forward)
4. Holder Location Identification Mark
IMPORTANT: Be sure to install thrust bearings, 1, on

the rear side of the upper, 2, and lower, 3, bearing 1
holders. Position thrust bearings with oil grooves, 4, 2
facing outward from bearing holders.
3
4
10044368 1
151
10-80
IMPORTANT: Be sure to install thrust bearing, 5, on
the front side of the upper bearing holder, 6. Position 7 5
thrust bearing with oil grooves, 7, facing outward 6
from bearing holder.
10044369
152
PORT BLOCK
4
Removal
NOTE: The oil pump shaft and port block assembly
is a press fit in the block.
1. Using special Tool No. (NH #NH11097, CIH

#CAS2779), 3, place the collars in the grooves of
the port block assembly.
2. Align the set screws, 2, of the puller, 3, with the
counterbores in the collars and tighten. 3 2
3. Using a sliding hammer, 1, remove the port block. 1
4. Remove plate, 4, from the block. 153
Installation
1. Using special Tool No. (NH #NH00117, CIH
#CAS2778), 2, insert the threaded guide pins, 1, 1
into the cylinder block.
2. Assemble the oil pump shaft to the port block us-
ing nut and washer.
3. Insert the port block assembly into the installer
and place on the guide pins.
4. Using a suitable driver, install the port block as-
sembly. The installer must bottom against the en-
gine block when fully positioned. 2
NOTE: Plate, 4, must be removed from engine block 154
for proper installation of the port block.
10-81
Op. 10 106
TIMING GEAR
1. Check the timing gears for wear and damage on
the contact area. Replace if any defect is found.
2. Measure the backlash of gears with a feeler
gauge or dial indicator. If the allowable limit is ex-
ceeded, replace all timing gears.
Standard Allowable Limit

0.08 mm (0.003″) 0.25 mm (0.010″)
155
CAMSHAFT
8
Disassembly 6
1. Remove the slider, 1, from the camshaft gear. 4 5
2. Using a gear puller, remove the gear assembly, 3 2
2, spacer, 3, spacers, 4, spacer gear, 5, bearing,
6, and key, 8, from the camshaft, 7. 9
7
1
156
Inspection
1. Place the camshaft in a set of V-blocks and check
the runout using a dial indicator, 1. 1
2. Replace or straighten the camshaft if the runout
3. Using a micrometer, measure the height of the
camshaft lobes.
4. Replace the camshaft if any of the cam lobes are
worn to less than the following dimensions:
Valve Lobe: 34.1 mm (1.3425″)
Injection Pump Lobe: 42.8 mm (1.685″)
157
10-82
Assembly
8
1. Install bearing, 6, two spacers, 4, spacer gear, 5, 6
and spacer, 3. 4 5
NOTE: The spacer gear, 5, serves as a spacer only. 2
There is no other purpose for this gear. 3
9
2. Insert key, 8, into key slot on shaft and press the 7
gear assembly over the shaft onto the key. 1
158
Op. 10 103
FLYWHEEL
1. Inspect the ring gear for cracked, broken,
chipped, or worn gear teeth. If found damaged,
replace the ring gear.
2. If necessary, remove the starter ring gear using
a hammer and chisel to crack the ring gear.
3. To reinstall a new ring gear, heat the new ring
gear to 120 - 150°C (245 - 300°F) from the inside
only. Be careful not to overheat the ring gear
teeth. Use a temperature sensitive crayon to
mark the inside of the ring gear. Quench the ring
159
gear quickly to obtain a good shrink fit onto the
flywheel.
10-83
Op. 10 102
TIMING GEAR HOUSING 2

The timing gear housing, 3, contains the front oil seal,
1, power steering seal, 4, and the governor linkage 3
assembly, 2. See “Governor” in chapter 2, Fuel Sys-
tems, for governor linkage repair and replacement
procedures.
1
10044360 4
160
FRONT OIL SEAL AND STEERING PUMP

SEAL
2
Replacement
1. Remove the front oil seal, 1, from the timing gear 3
cover, 3, and insert a new oil seal in its place.
2. Remove the steering pump seal, 4, located on
the front of the timing gear cover, and replace
with a new seal. 1
10044360 4
161
10-84
Op. 10 103
1
CRANKSHAFT AND BEARING HOLDER
Installation
1. Install the crankshaft with bearing holder through
the rear of the cylinder block.
2. Align the threaded holes on the bearing holders
with the bolt holes in the cylinder block.
3. At the flywheel end install the two socket head
hex bolts, at each center bearing install the hex
head bolt. Torque the socket head bolts to 24 - 31
N⋅m (18 - 22 ft.-lbs.). Torque the hex head bolts
to 49 - 54 N⋅m (36 - 40 ft.-lbs.). 162
1. Bearing Holder Bolts
4. Using a dial indicator, measure the crankshaft

end float (thrust).If the thrust is not within the al-
lowable limit, remove the crankshaft and check
the thrust washers.
Standard Thrust Allowable Limit

0.1 - 0.4 mm 0.5 mm (0.0195″)
(0.0039 - 0.0156″)
163
REAR OIL SEAL AND BACKPLATE
Installation
1. Install the rear oil seal, 1, over the rear of the
crankshaft.
NOTE: The rear oil seal is a press fit retained by the
backplate.
1
2. Apply liquid gasket sealer to the backplate at-
taching bolts,install the back and tighten the back
plate bolts to 14 - 18 N⋅m (10 - 13 ft.-lbs.).
164
10-85
FLYWHEEL
Installation
1. Fit the flywheel, 2, to the crankshaft, 1, and align
the bolt holes.
2. Install the flywheel retaining bolts and tighten to
69 - 78 N⋅m (51 - 57 ft.-lbs.).
2 1
165
Op. 10 105
1
PISTONS AND CONNECTING RODS
Installation
1. Coat the bearing faces, pistons, and piston rings
with clean engine oil. Slide the piston rings to per-
mit a sufficient amount of oil to be applied in the
grooves.
2. Set the piston ring gaps 90 degrees apart from
each other. Do not position these gaps toward
the piston pin or the right angle of the pin.
3. Using a piston ring compressor, 1, insert the pis-
tons in the cylinders with the prechamber side of 166
the piston facing the injection pump side. The
connecting rod marks should also face the injec-
tion pump side.
NOTE: Install the pistons from the front to the rear in
order.
4. Install the connecting rod caps, 2, making sure
the rod and cap matching marks align. Tighten 1
the connecting rod cap screws, 1, to 49-54 N⋅m 2
(36-40 ft. lbs.).
NOTE: After installation, ensure the crankshaft
moves freely. Ensure the axial play of 0.1 - 0.3 mm
(0.004 - 0.012″) is provided.
167
10-86
Op. 10 110
No. 1 No. 4
BALANCER ASSEMBLY (N844 and N844L
No. 2 No. 3
Engines)
Installation
NOTE: The balancer assembly on the N844 (D40,
DX40) engine is different than the balancer assembly
on the N844L (D45, DX45) engine due to the N844L
engine’s different connecting rods and longer piston
stroke.
1. Position the cylinder block with the oil pan mount- 20002376A
ing surface facing down.
168
2. Position the No. 1, and the No. 4 pistons at top
dead center.
IMPORTANT: When positioning balancer assembly
for installation to engine, be sure balancer weights
are oriented with weights down towards oil pan (flats
on weights should be facing as shown).
10044365
169
3. With the balancer weights centered straight
down (weights facing away from engine block),
position the balancer assembly, 5, and the origi- 4 6
nal quantity of shims, 4 (if used) on the cylinder
block, 6, using the dowel pins for alignment.
4. Install the retaining bolts, 3, and tighten to 49 - 4
53.9 N⋅m (36.2 - 39.8 ft.-lb.).
5. Install the oil transfer pipe, 2, and secure with the
banjo bolts, 1. 3
5
NOTE: If required, inspect the backlash between the
balancer gear and the drive gear. Adjust the backlash 1
20002374
2
to 0.2 - 0.4 mm (0.008 - 0.016 in.) using shims.
170
Balancer Shims
Engine Model Shim Thickness

N844 D40, DX40 0.1 mm (.004 in.)
N844L D45, DX45 0.2 mm (.008 in.)
10-87
OIL SUCTION PIPE AND SUCTION

STRAINER
Installation
1. Install a new O ring on the suction pipe and rotate
the suction pipe into its bore.
2. Install the suction strainer over the suction pipe
and align the bolt holes.
NOTE: If suction strainer bolt holes do not align, the
suction pipe is either too far into its bore or not in far
enough. Adjust as needed.
10044356 N843L Shown
3. Install the strainer retaining bolts and tighten to
171
8.8 - 12.9 N⋅m (6.5 - 9.5 ft.-lbs.).
OIL SUMP
Installation 1
1. Apply a thin coat of gasket sealer to the oil sump
sealing area.
2. Install a new gasket, the oil sump and the retain-
ing bolts. Tighten the retaining bolts, 1, diago-
nally and evenly.
172
Op. 10 106
CAMSHAFT AND CAMSHAFT GEAR 1

Installation
2
1. Install the front plate, 1, and gasket on the mount-
ing dowels and tighten the retaining bolts.
2. Carefully insert the camshaft into its bore so as
not to damage the bearings or bearing surfaces.
3. Align the retaining plate, 2, to the block bolt holes,
and install the retaining bolts, 3. Tighten the bolts
3
to 8.8 - 12.9 N⋅m (6.5 - 9.5 ft.-lbs.).
10044355
173
10-88
Op. 10 106
IDLER GEAR, OIL PUMP AND INJECTION 4

TIMING 1
Installation
1. Install the thrust washer, on the idler gear shaft. 5
2. Align the timing marks, 1, on the idler gear, 3,
crankshaft gear, 5, and the camshaft gear, 4.
3. Complete the installation of the oil pump and ad- 3
just axial clearance. See “Oil Pump Installation
and Adjustment” discussed later in this section. 10044361
2
NOTE: Do not turn the crankshaft until the timing 174
gear cover is installed.
NOTE: Number 3 piston (cylinder next to the fly-

wheel) will be at top dead center when timing marks
align. (3 cylinder engines only).
On 4 cylinder engines, there is not any relationship
to top dead center of any cylinder, when the timing
marks are aligned.
TIMING GEAR COVER

1
Installation
1. Install new cover gasket.
2. Insert the governor linkage through the block.
3. Rotate the oil pump cover to position the spring
pin hole, 2, to align with spring pin in timing cover.
4. Install cover locating pin in the oil pump cover
plate.
5. Install the cover retaining bolts, 1.
175
10-89
CRANKSHAFT PULLEY
Installation
2
1. Align the keyway on the crankshaft pulley, 2, and

the crankshaft, 3. Push the pulley onto the shaft.
2. Install the retaining nut, 1, and torque to 274.4 -
1
333.2 N⋅m (202.5 - 245.9 ft.-lbs.).
3
20002373
176
FUEL INJECTION PUMP
Installation 2
1. Insert the injection pump, 2, and shim in position
in the block. Connect the injection pump control
rack and governor link with the snap pin, 1.
3
2. Push the injection pump, 2, onto its mounting 3
studs, 3, and install the retaining nuts and bolts.
177
10-90
HYDRAULIC OIL PUMP

Installation
1. Mount the hydraulic oil pump, 3, on the timing 2. Remove the two nuts, 1, from the retaining
case cover, and install the retaining studs, 2. studs, 2.
3
20002372 2
178
POWER STEERING PUMP
Installation
1. Mount the power steering pump in position on the
timing gear cover with two retaining bolts (not
shown), and two retaining nuts, 1.
30996393
179
2. Attach the pressure tube, 4, to the bottom of the
steering pump, 3. 2
3. Install the suction line, 2, on the suction tube and
install the hose clamp, 1. 1
30996355 4
180
10-91
Op. 10 101
HEAD GASKET SELECTION

During assembly, the ultimate engine compression
ratio is established by the thickness of the head gas-
ket used. For service replacement, head gaskets of
different thickness are available. The correct head
gasket must be selected based upon the amount the
piston protrudes above the face of the block when at
top dead center. The correct head gasket usage is
determined as follows:
1. Position each of the pistons at top dead center 20002377

and, using a dial indicator, determine the dis-
tance each piston projects above the face of the 181
block.
NOTE: Measure each of the pistons while holding a
slight down pressure on the piston. Use the dimen-
sion taken from the cylinder which has the greatest
projection and select a head gasket as indicated in
the following chart.
NOTE: The variation in the amount of protrusion

among all pistons must be within 0.1 mm (0.004 in.).
Selection Chart
Model Measurement Value Head Gasket Part No. Installed Thickness
N843L 0.45 - 0.6 mm (0.0177 - 0.024 in.) 111147490 1.3 mm (0.0512 in.)
(D35)
(DX35) 0.6 - 0.7 mm (0.024 - 0.028 in.) 111147500 1.4 mm (0.0551 in.)
N844 0.5 - 0.6 mm (0.0197 - 0.0236 in.) 111147510 1.2 mm (0.0472 in.)
(D40)
(DX40) 0.6 - 0.7 mm (0.0236 - 0.02756 in.) 111147520 1.3 mm (0.0512 in.)
N844L --0.3~-0.45 mm (--0.0118~ - 0.0177 in.) 111147580 0.4 mm (0.0157 in.)
(D45)
(DX45) --0.2~-0.3 mm (--0.00787~ - 0.0118 in.) 111147590 0.5 mm (0.0197 in.)
CYLINDER HEAD
Installation 1
1. Install the valve tappets, 1.
182
10-92
2. Select the proper head gasket and place it on the
block with the side marked with the last four digits 11 9 13
of the part code no. up.
5
3. Tighten the head bolts in the sequence as 3

shown. Tighten first to half torque value, then to
1
the final torque specification of 98 - 103 N⋅m 2 7
(72.3 - 76 ft.-lbs.).
4
4. Replace the push rods and valve stem caps in 12
their original location.
8 6
5. Install the rocker shaft support assembly onto the 14 10
head and tighten the bolts to 27 - 39 N⋅m (20 -
29 ft.-lbs.). Model D35, DX35
183
20002380 Model D40, DX40, D45, DX45
184
Op. 10 106
1
VALVE CLEARANCE
2
Adjustment
1. Adjust the rocker arm to valve clearance. Be sure 3
the tappet is in its lowest position before making
the adjustment. To be sure the tappet is in its low-
est position, bring the piston to top dead center
on the compression stroke (both valves closed).
2. Loosen the nut and adjust the clearance of both
the intake and exhaust valves to 0.2 mm (0.008″)
with the adjusting screw. 20002378
185
1. Adjusting Screw
2. Locknut
3. Valve Clearance 0.2 mm (0.008″)
10-93
VALVE COVER
5
Installation 4
1. Install a new gasket, 1, and position the valve 3
cover, 2, over the rocker arms.
2
2. Install the valve cover retaining bolts, 3, and
tighten to 12 - 16 N⋅m (9 - 19 ft.-lbs.).
3. Install and tighten the seal washer, 4, and cap
nuts, 5.
1
10044353
186
WATER PUMP AND COOLING FAN

Installation
Install the water pump and fan assembly. See “Water
Pump Installation” discussed later in this section.
EXTERNAL OIL TUBE

Assembly
Connect the external oil tube to the cylinder head and
on side of engine block. Tighten the banjo bolt, 1, to
10 - 13 N⋅m (7 - 9 ft.-lbs.).
NOTE: The banjo bolt has oil port holes drilled in it. 1
Do not use a standard bolt in its place.
19988040
187
10-94
GLOW PLUG AND CONNECTOR

2
Installation
1. Install the glow plugs, 1, and torque to 15 - 20 N⋅m
(11 - 14.5 ft.-lbs.).
2. Install the glow plug connector, 2.
188
FUEL INJECTOR
2
Installation
Install the fuel injectors, 1, and torque to 60 - 69 N⋅m
(43.4 - 50 ft.-lbs.).
189
Op. 10 218
2 4 2
FUEL PIPING
Installation
1. Install the fuel return line, 4, on the injectors, 2,
and injector pump, 3. 3
2. Install the injection piping, 1, and torque to 15 -
24 N⋅m (11 - 18 ft.-lbs.).
190
10-95
ALTERNATOR AND TEMPERATURE

2 1
SENDER SWITCH
Installation
1. Install the temperature sender switch, 1, and 4
torque to 25 - 29 N⋅m (18 - 21.7 ft.-lbs.).
2. Install the alternator with its mounting bolts, 2,
snug.
3. Install the V-belt, 3, adjust to 10 - 15 mm (0.2 - 0.4″)
2
deflection tension, and tighten the alternator bolts.
3
4. Connect the wiring to the back of the alternator
at location 4.
191
EXHAUST MANIFOLD
Installation
Install the exhaust manifold, 2, gasket and muffler, 1.
192
10-96
DESCRIPTION OF OPERATION -- ENGINE LUBRICATION SYSTEM
Op. 10 304 crankshaft to the three connecting rod bearings. The

The oil pump assembly is located within the idler gear remaining portion of the oil flow is directed through
at the front of the block, below and to the left of the the external tube to the rocker arm assembly. Oil
crankshaft as viewed from the front of the engine. flows from the external tube into a passage in the
The oil pump is driven by the crankshaft gear. rocker arm bracket to the rocker arm shaft. Oil leak-
age from clearance between the rocker arms and the
Oil is picked up from the sump through the suction shaft overflows in the valve cover and lubricates the
strainer and intake tube and drawn into the lower side valve stems, push rods, and tappets. The relief valve
drilling in the block to the oil pump. Oil from the pump is mounted on the side of the engine block and inter-
flows through passages in the block, past the relief sects the main oil passage. When the oil pressure ex-
valve, through the oil filter and returns to the main oil ceeds the rated pressure, oil is bypassed through the
gallery in the area of the drilled bolt located on the relief valve directly to the sump. The cylinder walls,
side of the block. Oil flow in the main oil gallery ex- pistons, and piston pins are splash lubricated by the
tends to the four main bearings. Oil flow to the main crankshaft.
bearings passes through drilled passages in the
10-97
3
2
5
10044362 1
193
1. Oil Pump 4. Oil Pressure Switch
2. Relief Valve 5. Suction Strainer
3. Oil Filter
10-98
MODEL N843L -- D35, DX35
10-99
MODEL N844 and N844L -- D40, DX40, D45, DX45
10-100
Op. 10 206
1
OIL FILTER
Construction and Function
These engines utilize a cartridge type filter. Pressur-
ized oil flow from the pump enters from 1, and is fil-
tered by a full flow filter before discharge through 2. 2
When the full flow filter is clogged, the safety valve,
3, opens to bypass the oil.
3
194
Maintenance
The oil filter must be replaced every 100 hours of op-
eration. When installing a new filter, coat its face with 7
clean oil. Hand tighten only. 6
5
Op. 10 304
4
OIL PUMP 3
2 9
Removal 1
1. Drain the engine oil and remove the spin-on type
8
oil filter.
2. Drain the radiator and remove the cooling fan
and water pump assemblies. See “Cooling Fan 195
Removal” and “Water Pump Removal” dis-
cussed later in this section.
3. Remove the timing gear cover. See “Timing Gear
Cover Removal” discussed earlier in this section.
4. Remove the retaining ring, 1. Remove the idler
gear, 8, and oil pump assembly, 1 through 9.
Inspection
1. Check for excessive wear on the pump cover, 5,
and the port block. If port block requires replace-
ment, see “Port Block Removal” discussed ear-
lier in this section.
2. Inspect the pump shaft and rotor, 6, for excessive
wear or scratches.
10-101
3. Measure the rotor to vane clearance. Replace
CLEARANCE
the components as required, if clearance is not
within specified tolerances.
Std. Max.
0.01 - 0.15 mm 0.25 mm
(0.004 - 0.006″) (0.010″)
196
Installation and Adjustment
1. If the port block assembly was removed, install a
new port block assembly. “See Port Block As-
7
sembly Installation” discussed earlier in this sec- 6
tion. 5
2. Install the thrust washer, 9, and align the set 4
marks on the idler gear, 8, crankshaft gear, and 3
camshaft gear, and install the idler gear on the 2 9
port shaft. 1
8
3. Install the rotor, 6, and spring, 7.
4. Install the oil pump cover, 5, shim, 4, spring, 3,
and collar, 2. Secure the assembly to the shaft
with the retaining ring, 1. 197
5. Using a dial indicator, 1, measure the axial move-

ment of the collar, 6. The standard clearance is 6
2
0.01 - 0.15 mm (0.00039 - 0.0059″) and the max- 1
imum allowable is 0.2 mm (0.0079″). Install or re- 4
move shims, 5, (PN SBA-199286340) as needed 5
to obtain the standard clearance value.
3
6. Install the water pump and cooling fan assembly.
See “Water Pump Installation” discussed later in
this section.
7. Install the timing gear cover. See “Timing Gear
Cover Installation” discussed earlier in this
section.
8. Refill the radiator to its proper coolant level. 198
9. Replace the engine oil filter and fill the sump 1. Dial Indicator
with oil. 2. Spring
3. Idler Gear
4. Oil Pump Cover
5. Shim
6. Collar
10-102
ENGINE OIL PRESSURE

2
Check 1
1. Disconnect the sending lead, 2, and remove the
oil pressure sending unit, 1.
199
NOTE: Main gallery access port, 1, located next to
the relief valve, 2, and external oil tube, 3. 3
2
1
20002360
200
2. Install the oil pressure test fitting No. (NH
#NH00011, CIH #CAS2791), 1, and test gauge, 2
2. Start the engine and observe gauge indicator.
Gauge should indicate between 0.98 - 1.47 bar
(14.22 - 21.33 psi) at low idle and 2.45 - 3.43 bar
(35.5 - 49.8 psi) at high idle.
NOTE: Pressure test should be with engine at nor- 1
mal operating temperature.
3. If the gauge did not indicate the oil pressure

within specified tolerances at low and high idle,
troubleshoot the lube oil system. See “Trouble-
shooting” discussed later in this section.
201
10-103
OIL PRESSURE RELIEF VALVE

Removal
Unscrew the oil pressure relief valve, 1, and remove
from the block.
NOTE: Pressure test should be with engine at nor-

mal operating temperature.
Installation
Install a new O-ring seal over the relief valve and
screw the valve into the block. Tighten to 58.8 - 68.6 20002379
N⋅m (43.4 - 50.6 ft.-lbs.).
202
OIL CONSUMPTION
Log oil consumption as follows:
1. Change the engine oil and filter. Use the oil speci-
fied in the loader operator’s manual.
2. Run the engine for 2 minutes.
3. Check the dipstick and add oil, if required, so the
level is at the full mark.
4. Fill the fuel tank with fuel.
5. Record fuel consumption in liters (gallons), oil
added in liters (gallons), and hour reading. Re-
cord fuel and oil use for 100 hours of operation,
which is the recommended oil change interval.
Check the dipstick before running the engine
each day.
The maximum allowable oil consumption is 0.8%.
The following table gives examples:
Fuel Consumption, Liters (Gallons) Oil Consumption, Liters (Quarts) Percentage

189.27 L (50 gal) 1.5 L (1.6 qts) 0.79%
378.54 L (100 gal) 3.03 L (3.2 qts) 0.80%
757.08 L (200 gal) 6.06 L (6.4 qts) 0.80%
If the oil consumption is greater than 0.8% of the fuel
consumption, oil usage is excessive. A sample cal-
culation for oil consumption follows:
Quantity of Oil in Liters (gallons)
% consumption = × 100
Quantity of Fuel in Liters (gallons)
Assume 0.25 Liters (0.07 gallons) oil is added for 50

Liters (13.2 gallons) fuel.
0.25 L 0.07 gallons
% consumption = × 100 or × 100
50 L 13.2 gallons
% consumption =0.5%
10-104
DESCRIPTION OF OPERATION -- COOLING SYSTEM
Op. 10 400 to flow through the thermostat bypass to the radiator

The cooling system is the recirculating bypass type to effect a faster warm-up. When the thermostat is
with a full length water jacket for each cylinder cast open, the coolant flows from the water outlet connec-
into the block. The coolant is drawn from the bottom tion to the top tank of the radiator for maximum cool-
of the radiator by the water pump and passes around ing.
the cylinders and into the cylinder head.
Cooling occurs as the coolant passes down through
The thermostat is located in the front of the cylinder the radiator cores which are exposed to the air
head and thermostatically controls the flow of coolant flow created by the fan as air is drawn through the
from the engine to the radiator. When the thermostat radiator.
is closed only a small amount of coolant is permitted
10-105
203
10-106
MAINTENANCE Drain and flush the cooling system every twelve

months and replace the coolant with fresh antifreeze
WARNING and pure water.
The cooling system operates under pressure
which is controlled by the radiator cap. It is dan- After the coolant has been drained from the radiator
gerous to remove the cap from a hot engine or and block, flush the system by placing a water hose
while the engine is running. Always shut the en- in the radiator filler neck. With the drain open and the
gine off and allow it to cool before removing the system full of water, start the engine and run it until
radiator cap. When removing the cap, use a thick the water flowing from the drain is clear. Stop the en-
cloth to cover the cap and slowly turn the cap to gine and allow the system to drain, then replace the
the first stop to allow pressure to escape before coolant with new 50/50 mixture antifreeze and pure
removing the cap completely. water.
Clean the cooling system to remove rust, sludge, and RADIATOR CAP
other foreign material by using a coolant system The radiator cap acts to pressurize the cooling sys-
cleaning solvent. In severe cases, pressure flushing tem, as a pressure relief valve and also acts as a vent
may be required. A pulsating or reverse flow flushing valve. The pressure valve permits a limited pressure
will more effectively loosen and remove foreign ma- buildup in the cooling system as the coolant heats up.
terial than a steady flushing in normal direction of This increased pressure increases the boiling point
coolant flow. If pressure flushing is to be used, always of the coolant. If excess pressure builds up in the sys-
remove the thermostat and make sure the head bolts tem, the pressure relief valve will open until the pres-
are tightened properly. sure returns to the proper level, 0.9 bar (13 psi).
COOLANT When the engine is shut off and the coolant cools, a
vacuum condition is created in the system. A vent
The coolant is a permanent type ethylene-glycol valve in the radiator cap opens to permit outside air
base antifreeze and should be used all year. pressure to enter the system when this condition
exists.
10-107
Op. 10 402
THERMOSTAT
The thermostat, 1, is located between the coolant
outlet on the engine and the radiator. In this position
the thermostat is able to sense the coolant tempera-
ture in the engine and regulate the flow of coolant to 1
the radiator. When the engine is cold, only a small
amount of coolant flows to the radiator through the
thermostat bypass. As the engine warms up, the
thermostat opens to allow sufficient coolant flow to
the radiator to maintain a constant engine
temperature.
204
Op. 10 402
WATER PUMP 1
The water pump, 1, is an impeller attached to a shaft
which is belt driven by the engine crankshaft. The im-
peller circulates water by centrifugal force. Coolant
entering the pump housing from the radiator through
the lower hose is thrown outward against the housing
with sufficient force to cause a circulating action.
205
Op. 10 414
COOLING FAN
A seven-blade cooling fan, 1, is belt driven by the en-
gine crankshaft and is mounted on the water pump
shaft. The cooling fan is positioned behind the radia-
tor to draw air over the radiator cooling fins. To in-
crease and concentrate the volume of air flowing
through the radiator, a shroud is positioned around
the fan.
206
10-108
OVERHAUL -- COOLING SYSTEM
Op. 10 406
RADIATOR 2
1
Removal
1. Drain the radiator coolant at tap, 1, and engine
block at petcock, 2, in a clean container. Remove
the radiator cap to assist draining.
10044363
207
2. Remove the upper, 1, and lower, 2, radiator

hoses from the radiator, 3.
1
30996394
208
3. Loosen the clamp, 1, on the air inlet hose, 2. Re-
1 2
move the inlet hose, 2, from the air cleaner, 3.
10998354
209
10-109
4. Loosen and remove the radiator mounting bolt,
1, from the radiator, 2. Repeat for the opposite
side.
2
5. Loosen and remove the radiator support brace,
and remove the radiator from the tractor.
10034982 1
210

1. Inspect the radiator fins and be sure they are free
from obstruction.
2. Check the radiator for signs of coolant leakage
and repair as required.
Installation
1. Place the radiator assembly, 2, in position on the
tractor frame.
2
2. Install and tighten the radiator mounting bolts, 1.
3. Install the radiator top support brace.
10034982 1
211
4. Install the air cleaner inlet tube, 2, onto the air

1 2
cleaner, 3, and secure with the clamp, 1.
10998354
212
10-110
5. Install the upper, 1, and the lower, 2, radiator
hoses on the radiator, 3. Secure with the spring
1
clamps.
30996394
213
6. Close the radiator drain tap, 1, and engine block
petcock, 2.
2
7. Replace the coolant with 50/50 mixture anti-
1
freeze and pure water.
8. Install the radiator cap. Start the engine and run
for several minutes and check the hose connec-
tions for any leakage.
10044363
214
Op. 10 402
1
WATER PUMP
Removal
1. Remove the radiator assembly. See “Radiator
Removal” discussed previously in this section.
2. Loosen the alternator mounting bolts, 1, and ad-
justing bracket and remove the drive belt, 2.
1
2
215
10-111
3. Remove the attaching bolts, 4, cooling fan, 1, fan
holder, 2, and pulley, 3.
1 4
216
4. Remove the bypass hose, 1, and lower radiator
hose, 2, from the water pump, 3. 6
7
5. Remove the water pump retaining bolts, 8, and 1
remove the water pump, 3, and gasket, 5, from
engine.
6. Remove the water pump mounting plate, 4, and 3
gasket, 6.
4
5
2
8
217
1. Bypass Hose
2. Lower Radiator Hose
3. Water Pump
4. Mounting Plate
5. Gasket
6. Gasket, Mounting Plate
7. Retaining Bolt, (Mounting Plate)
8. Water Pump Retaining Bolt
10-112
Inspect the water pump for indications of coolant
leakage from around the pump shaft. If coolant leak-
age is evident, or if the water pump is noisy when run-
ning, replace the water pump.
Installation
6 7
1. Install the water pump mounting plate, 4, and
new gasket, 5.
1
2. Install the water pump, 3, and new gasket, 6, and
tighten the retaining bolts, 7 and 8.
3. Install the bypass hose, 1, and lower radiator 3
hose, 2, on the water pump and tighten the hose
clamps. 4
5
2
8
218
4. Install the pulley, 3, fan holder, 2, and cooling fan,
1, and tighten the attaching bolts.
219
5. Install the drive pulley and adjust the alternator
drive belt tension to obtain a deflection, 1, of 5 -
10 mm (0.2 - 0.4″) when 5 kg (11 lbs.) is applied
between the pulleys and tighten the alternator
mounting bolts.
6. Install the radiator assembly. See “Radiator
Installation” discussed earlier in this section.
220
10-113
Op. 10 402
THERMOSTAT
1
Removal
1. Remove the radiator cap.
2. Open the radiator drain tap, 1, and collect the
coolant in a clean container.
10034982
221
3. Remove the radiator hose, 6, and bypass hose,

7, from the thermostat housing, 2. 5 6
4. Remove the retaining bolts, 8, and remove the 8
thermostat cover, 5, gasket, 4, thermostat, 3, and
gasket, 1. 4
3
1
2
7
222
1
1. Place the thermostat, 3, in a container filled with
a 50/50 mixture of antifreeze and water. Insulate 2
the thermostat from the bottom of the container. 3
2. Place a high temperature thermometer, 1, in the
coolant mixture and heat the container.
3. Use a 0.08 mm (0.003″) feeler gauge, 2, to deter-
mine when the thermostat begins to open.
4. Note the coolant temperature at which the ther-
mostat starts to open and when it is fully opened.
5. Replace the thermostat if it fails to open at the
specified temperature.
223
Thermostat opening temperature:
Start to open: 80-84°C (176-183°F) - All models
Fully open: 95°C (203°F)
6. Thoroughly clean the gasket mating surfaces be-
fore installing thermostat.
10-114
Installation
1. Attach gasket, 1, and thermostat housing, 2, to 5 6
the engine block.
8
2. Place the thermostat, 3, in position in the thermo-
stat housing, 2. 1 4
3. Install the gasket, 4, and thermostat cover, 5, and 3
tighten the retaining bolts, 8.
1
4. Install the radiator hose, 6, and bypass hose, 7, 2
on the thermostat housing, 2, and tighten the
hose clamps. 7
5. Close the radiator drain and refill the radiator with
50/50 mixture of antifreeze and pure water.
224
6. Install the radiator cap and start the engine and
run for a few minutes to check for any leakage.
CAB HEATER
Installation
NOTE: If a cab heater is to be installed, use the fol-
lowing steps to correctly locate the installation points
for connection to the tractor’s cooling system.
1. Loosen the radiator drain petcock, and drain the
coolant into a suitable container. 1 2
2. Remove the plug, 1, from the thermostat hous-
ing, 2, and install the heater inlet (IN) fittings into
the thermostat housing.
30997563
225
3. Remove the plug, 1, from the top of the water
pump, 2, and install the heater return (OUT)
fittings. 1
4. Follow the instructions provided with the heater
kit, for further installation instructions.
2
226
10-115
10-116
SECTION 10 - ENGINE
Chapter 2 -- Fuel Systems
CONTENT

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Standards for Adjusting Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
10 242 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Troubleshooting -- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting -- Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting -- Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10 244 Fuel Variation Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Delivery Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 244 CTD (Compact Timing Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
10 236 Pumping Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 214 Delivery Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
10 242 Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Calibration/Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 230 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spill-Timing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fuel Screw/High Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10 230 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Auto Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
10 230 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10-1

10 218 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Assembly/Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Engine Breather Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Troubleshooting -- Engine Breather Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10-2
SPECIFICATIONS
Table 1
INJECTION PUMP D35, DX35 (N843L) D40, DX40 (N844) D45, DX45 (N844L)
Pump Manufacturer Assembly BASC BASC BASC
Number 104135- 3050 104134- 4030 104135- 4020
Type In-Line In-Line In-Line
Timing (Before TDC) 17 - 19° 19 - 21° 17 - 19°
Timing (Piston Height at Injection: 2.854 - 3.554 mm 3.199 - 3.895 mm 2.854 - 3.554 mm
Start BTDC) (0.1123″ - 0.1399″) (0.1259″ - 0.1533″) (0.1123″ - 0.1399″)
Injection Nozzle
• Nozzle Type Throttle Throttle Throttle
• Needle Valve Diameter 0.4 mm (0.157″) 0.4 mm (0.157″) 0.4 mm (0.157″)
• Pintle Diameter 1.0 mm (0.039″) 1.0 mm (0.039″) 1.0 mm (0.039″)
Injection Pressure 147 bar 147 bar 147 bar
(2150 psi) (2150 psi) (2150 psi)
Spray Angle 4° 4° 4°
Service Adjustments
• Idle Speed 1000 - 1100 rpm 1000 - 1100 rpm 1000 - 1100 rpm
• Max. No-Load Speed 2815 - 2855 rpm 2815 - 2855 rpm 2815 - 2855 rpm
TORQUE SPECIFICATIONS
Delivery Valve Holder 39.2 - 44.1 N⋅m 39.2 - 44.1 N⋅m 39.2 - 44.1 N⋅m
(28.9 - 32.5 ft. lbs.) (28.9 - 32.5 ft. lbs.) (28.9 - 32.5 ft. lbs.)
Injector Assemble 59 - 69 N⋅m 59 - 69 N⋅m 59 - 69 N⋅m
(43 - 51 ft. lbs.) (43 - 51 ft. lbs.) (43 - 51 ft. lbs.)
* BASC -- Bosch Automotive Systems Corporation
STANDARDS FOR ADJUSTING THE INJECTION PUMP
Use the following standards when checking or adjusting the fuel injection pump, or after field rebuilding of the
pump.
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise, viewed from driving side
Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NP-DN4PDN117
Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105148-1210
Nozzle Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 bar (2150 psi)
Injection Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 mm inside diameter x 6 mm outside diameter - 320 mm long
Oil Flowing Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 bar (2.8 psi)
Test Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light Oil
10-3
TORQUE SPECIFICATIONS
Injection Pump Retaining Nuts and Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5 - 6.8 N⋅m (3.3 - 5.0 ft. lbs.)
SPECIAL TOOLS
Injector Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #FNH01721, CIH #OEM1064
Injector Adapter Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #FNH01728, CIH #OEM23622
10-4
9
1 10
5 11
7 12
13
8 14
1
1. Five-Sided Bolt 6. Plunger Barrel 11. Eye Bolt
2. Sleeve Flange 7. Control Sleeve 12. Plunger
3. Delivery Valve Spring 8. Tappet 13. Control Rack
4. Delivery Valve Seat 9. Delivery Valve Holder 14. Plunger Spring
5. Delivery Valve 10. Pump Housing
Op. 10 242 The plunger then ascends, and when the plunger
barrel’s suction and discharge port is closed by the
INJECTION PUMP plunger, the fuel oil pressure increases. The fuel oil
The injection pump is mounted in the engine’s cylin- then raises the delivery valve, 5, and is delivered
der block. It does not have a camshaft, but is driven through the injection pipe to the nozzle holder. When
by the engine’s camshaft. Plunger, 12, movement is the fuel oil pressure exceeds the force of the nozzle
constant, being raised by tappet, 8, and returned by spring’s set force, fuel is injected into the engine’s
the plunger spring, 14, as the engine rotates. The combustion chamber in the form of a fine spray.
plunger barrel’s, 6, suction and discharge port opens
onto the pump housing’s fuel oil chamber, which is al- The plunger further ascends, and when the plunger
ways filled with fuel. helix meets the plunger barrel’s suction and dis-
charge port, fuel delivery ends (at the same time in-
When the plunger descends, fuel oil is sucked into jection from the nozzle ends). The delivery valve is
the plunger barrel, and when the plunger reaches it’s then closed by the set force of the delivery valve
lowest point, the suction of fuel oil stops. spring so that fuel oil is no longer delivered, even
though the plunger continues to ascend.
10-5
The effective stroke is from the moment that the
plunger barrel’s suction and discharge port is closed
by the end of the plunger (beginning-of-injection) un-
til the suction and discharge port meets the plunger
helix (end-of-injection). The effective stroke can be
altered by rotating the plunger. Accordingly, the rela-
tionship between injection quantity and effective
stroke is proportional.
20000731
2
10-6
TROUBLESHOOTING -- GENERAL
CONDITION CAUSE REMEDY

Fuel not reaching injection point Fuel shutoff valve closed Open the fuel shutoff valve
Restricted fuel filter Check and flush the fuel filter clean
Faulty fuel stop solenoid Check fuel stop solenoid. See

“Fuel Stop Solenoid” Section 55,
Electrical System
Air in fuel system Check for air leaks on the suction

side of system. Bleed the fuel
system
Fuel leakage Check the condition of the fuel lines

and connections for tightness or
possible damage
Fuel reaching nozzles but engine Low cranking speed Check cranking
will not start
Incorrect throttle adjustment Check throttle control or travel
Incorrect pump Check pump timing
Fuel Leakage Check all fuel lines for leakage or

possible damage
Faulty injectors See “Troubleshooting - Fuel

Injectors” later in this section
Low compression Check for air leaks on the suction

system
Engine hard to start Low cranking speed Check cranking
Incorrect throttle adjustment Check throttle control or travel
Restricted fuel filter Check and flush fuel filter clean
Contaminated fuel Check for water in fuel
Low compression Check engine compression. See

“Engine Compression Test”,
Section 10
Air in fuel Check for air leaks on the suction

side of system. Bleed the fuel sys-
tem
10-7
Engine starts and stops Low cranking speed Check cranking
Restricted air intake Check for restrictions in the air in-

take

tem
Engine overheating Check cooling system
Erratic engine operation (surge, Fuel leakage Check all fuel lines for leakage or
misfiring, poor governor regula- possible damage
tion)
Fuel starvation Check and flush clean restricted
fuel lines

tem
Faulty or sticking injector nozzles See “Troubleshooting - Fuel

Incorrect engine timing Check for improper valve adjust-

ment or faulty valve
Sticky hose cone Check nose cone for proper opera-

tion. Lubricate or replace if nose
cone is binding on end of camshaft
Engine does not develop full power Incorrect throttle adjustment Check for insufficient throttle
or speed movement
Incorrect Maximum no-load speed Check maximum no-load speed

adjustment
Fuel starvation Check and flush clean restricted

fuel lines and filter

tem
Incorrect timing Check pump timing

tem

10-8
Engine emits black smoke Restricted air intake Check for restrictions in the air in-
take
Engine overheating Check cooling system
Incorrect timing Check pump timing
Faulty injectors See “Troubleshooting - Fuel


system

Pump fails to deliver fuel to all in- Blocked fuel lines to pump Remove fuel lines and flush or re-
jectors place
Air in system Check for air leaks on the suction

system
Control rod seized in “OFF” posi- Repair or replace control rod

tion
Pump fails to deliver fuel to one in- Air in fuel line to injector Bleed fuel line
jector
Plunger spring broken Replace spring
Plunger seized Repair or replace barrel and plung-

er assembly
Delivery valve seized Repair or replace delivery valve
Badly scored plunger and barrel Replace plunger and barrel

assembly
Governor fails to maintain maxi- Control spring broken Replace control spring
mum or minimum no-load fuel de-
livery Governor weights seized Repair or replace weight assembly
and/or camshaft
Governor weight carrier broken Replace weight assembly
Nose cone seized Replace nose cone and/or camshaft
Pump link spring broken Replace spring
10-9
TROUBLESHOOTING - FUEL INJECTORS

Nozzle does not “buzz” while in- Needle valve stuck Check needle valve for carbon
jecting build-up and binding
Excessive fuel leakage Check valve and valve seat for

scores or other indications of leak-
age
Nozzle damage Inspect faces and tighten nozzle

retaining nut
Nozzle leakage Needle valve worn Replace nozzle assembly
Blocked nozzle assembly Check for carbon or foreign matter

on faces of nozzle and nozzle hold-
er. Flush, clean, or replace
Loose nozzle retaining nut Inspect faces and tighten nozzle

retaining nut
Nozzle opening pressure incorrect Incorrectly adjusted nozzle retain- Check retaining nut for looseness
ing nut
Damaged nozzle or seized needle Replace nozzle assembly

valve
Blocked nozzle orifice Check orifice for carbon or foreign

matter. Flush clean or replace
Nozzle seat leakage Nozzle incorrectly seated Check for carbon or foreign matter
on faces of nozzle and nozzle hold-
er. Flush, clean, or replace
Sticking or binding needle valve Repair or replace nozzle assembly
10-10
TROUBLESHOOTING - GOVERNOR

Sluggish governor response Nose cone binding on camshaft Replace or lubricate nose cone on
end of camshaft
Fuel rack binding in injection pump Lubricate rack with penetrating oil
or submerse rack mechanism in
automatic transmission fluid. Re-
pair or replace injection pump
Governor weights binding on pivot Repair governor assembly

pins
Linkage arm between governor Straighten or replace linkage arm

linkage and injection pump rubbing assembly
on cylinder block
Binding of throttle arm pivot shaft Lubricate or replace throttle arm

shaft
Engine runs away (excessive Nose cone stuck at “in” position Replace nose cone or check cam-
speed) shaft for binding
Linkage arm between governor Repair or replace linkage arm as-

linkage and injection pump stuck sembly
Fuel rack stuck in full fuel position Lubricate or repair injection pump
Engine will not develop rated Fuel screw adjusted too far into en- Contact Case IH representative for
speed gine block adjustment
Fuel rack stuck in low fuel position Lubricate or repair injection pump
Engine speed surging Broken dampener spring on link- Replace dampener spring
age arm
Damaged governor spring Replace governor spring
Worn linkage Inspect and repair linkage as needed
10-11
Op. 10 244
FUEL VARIATION MECHANISM
As well as pressurizing the fuel oil, the injection pump
also functions to vary the fuel injection quantity.
A control sleeve is installed around the plunger bar-

rel, and a flange on the bottom of the plunger is in-
serted into a groove in the control sleeve. Teeth on
the control sleeve are engaged with teeth on the con-
trol rack so that movement of the control rack results
in rotation of the plunger and, consequently, variation
of the fuel injection quantity.
Non Delivery Partial Delivery Maximum Delivery
10-12
DELIVERY VALVE ASSEMBLY

The delivery valve assembly consists of the delivery
valve and the valve seat.
When the force of the high-pressure fuel oil delivered

by the plunger exceeds the force of the delivery valve
spring, the delivery valve opens and fuel oil is deliv-
ered through the injection pipe to the nozzle holder.
After injection, the injection pipe retains a degree of

residual pressure adequate for the subsequent injec-
tion. The delivery valve prevents the reverse flow of
this fuel oil in the injection pipe to the plunger side. If
the residual pressure is too high, then the flow of fuel
oil will not be properly cut after injection. 5
By allowing the fuel oil in the injection pipe to retract

an amount equal to the piston’s retraction stroke, the
delivery valve improves the ability of the nozzle to cut
injection, as well as preventing dribbling.
Op. 10 244
CTD (COMPACT TIMING DEVICE)
MECHANISM
NOTE: The CTD (Compact Timing Device) mecha-
nism is installed on the tractors to reduce noise,
smoke, and exhaust gas emission etc.
When the plunger descends, fuel oil is sucked into

the barrel, and when the plunger reaches its lowest
point, the suction is finished.
SUCTION
6
In case of the standard plunger, the plunger then as-
cends, and when the barrel’s main port is closed by
the plunger, the fuel oil pressure increases, and the
fuel delivery starts.
CTD type plunger (the barrel has sub port), whether

the fuel delivery starts or not is determined by the en-
gine’s rev speed. When the engine’s rev speed is low,
the delivery does not start, because the sub port is
still opened, and fuel oil pressure does not increase.
But, when the engine’s rev speed is high, the sub
port’s diameter is so small that it can be considered
as being closed. For this reason, fuel oil pressure in- DELIVERY START (HIGH SPEED)
creases and the delivery starts.
7
10-13
The plunger further ascends, and when the barrel’s
sub port is closed by the plunger, the fuel oil pressure
increases and the delivery starts, regardless of the
engine’s rev speed.
DELIVERY START (LOW SPEED)
8
The plunger further more ascends, and when the
plunger main lead meets the barrel’s main port, the
fuel oil pressure decreases, and the fuel delivery
ends.
DELIVERY END
9
The fuel injection pump, 1, is a constant stroke type
pump and has one pumping element for each cylin-
der. The injection pump operates at one-half engine
speed.
10
10-14
Op. 10 236
PUMPING ELEMENTS
The pumping elements are operated by cam lobes,
1, that are incorporated on the engine valve train cam 1
shaft, which is driven by the engine oil pump.
11
Op. 10 214
DELIVERY VALVES
Located above each pumping element is a delivery 1 2 3 4
valve assembly. The delivery valve consists of a de-
livery valve holder, 1, spring, 2, piston and stem as-
sembly, 3, operating within a cylindrical guide, 4,
which terminates in a conical seat. The lower part of
the stem has four vertical flutes which accurately lo-
cate within the guide while permitting fuel to pass.
Above the flutes is a piston which is a lapped fit in the
bore of the valve guide.
The delivery valve serves as a non-return valve and

also as a means of rapidly reducing the fuel pressure 12
in the injector line when injection ceases. Rapid pres-
sure reduction is required to be sure injector needle
valve “snaps” shut to prevent fuel “dribble”, a condi-
tion which can cause carbon formation on the injector
tip.
10-15
4
1
3 2
A. Valve Closed B. Valve Open C. Valve Closing
13
1. Piston 3. Conical Seat
2. Valve Guide 4. Spring
The delivery valve operates as follows: Position C: The helical groove has uncovered the in-
let port and released the fuel pressure. The delivery
Position A: The pump plunger is at the bottom of the valve spring, aided by the high pressure still existing
stroke and the inlet ports are uncovered, so the barrel in the pipeline, forces the delivery valve to close rap-
and delivery guides are filled with fuel. As the fuel is idly.
at low pressure, the delivery valve is retained on the
seat by spring pressure. During closing, the piston portion of the valve return-
ing into the guide increases the volume of the injector
Position B: The plunger has risen and closed both line by the volume of this part of the valve.
inlet ports, pressurized the fuel and the injection pro-
cess begins. The pressurized fuel overcomes the This sudden increase in the volume of the injector
spring tension, lifting the delivery valve off its seat un- line causes a rapid collapse of pressure and allows
til the piston is clear of the guide, permitting fuel to the injector needle valve to “snap” shut.
pass to the injector.
10-16
Op. 10 242
INJECTION PUMP 1
Removal
1. Turn the fuel shut-off valve, 1 to the opposition.
2. For easier access to the injector line nuts, re-
move the filter from the bracket by removing the
2
two nuts, 2.
30000725
14
NOTE: Four cylinder shown.
1
3. Remove the fuel injection lines, 1, by loosening
nuts, 2, on the injection pump and the nuts on the
injectors.
NOTE: Cap and plug all openings to prevent contam-
ination.
30000726
15
4. Disconnect the fuel tank return line by removing
bolt, 1. 1
5. Disconnect fuel inlet line, 2, by loosening clamp
screw, 3. 3
30000727
16
10-17
6. Disconnect the wire, 1, to the fuel shut-off sole-
noid, 2, and remove the fuel shut-off solenoid.
7. Remove the mounting nuts and bolts, 3. 3
1
30000728
17
8. Raise the pump and remove the snap pin, 3, and
separate the governor link, 2, from the pump con-
trol rack, 1.
9. Remove the injection pump from the engine. 3
NOTE: If there are shims between the pump mount-
ing flange and the engine block, carefully remove the
shims and retain for installation.
2
18
19
10-18
Repair
If the injection pump is suspected of being faulty, it
should be repaired by an authorized Diesel Service
Station only.
NOTE: If repair is within Case IH warranty period, re-

place injection pump with a new pump from the “Case
IH Parts Department”.
Installation
Installation generally follows removal procedures in 3 4
reverse. If the pump is being replaced or if the timing 5
is unknown, proceed to “Calibration/Adjustments”, 2
later in this section.
1. Attach the pump rack to the governor linkage.

2. Install injection pump assembly with shims into
engine housing.
3. Install the pump mounting nuts and bolts and
tighten to 13 - 17 N⋅m (9.4 - 12.3 ft. lbs.).
1
4. Install fuel solenoid, 1, into rear of injector hous- 30000729
ing and connect the electrical lead, 2. 20
5. Connect the fuel inlet line, 3, by tightening clamp
screw, 4.
6. Install the fuel return line by installing bolt, 5.
7. Install injector lines, 6, by tightening nuts, 7, at
the pump and nuts at the injectors. 8 6
8. If removed, reinstall the fuel filter onto its bracket
by tightening two nuts, 8. 7
9. Turn the fuel select, 9, to the on position.
After installation bleed air from the fuel system. See
“Auto Bleed”, later in this section.
NOTE: It may be necessary to verify pump timing. 9

Spill-time the pump as outlined in “Spill-Timing Pro-
cedure”, discussed in this section.
30000729
21
10-19
CALIBRATION/ADJUSTMENTS
Op. 10 230
FUEL PUMP
Installation (New Pump or Drive Component)
NOTE: Installation of a new pump is the same as
installation of an original pump. When installing a
new pump, however, checking the timing is required.
1
1. Position the pump in the block using a new shim
gasket, 1, of 0.3 mm (0.012″) thickness, or origi-
nal shim pack from removed pump.
22
2. Connect the governor link, 2, to the pump control
rack, 1, and secure with snap pin, 3.
1
2
23
NOTE: Check the control rack, 1, for any binding con-
ditions by moving the control lever back and forth.
Lubricate control rack with clean engine oil before
installation.
3. Install the mounting bolts and tighten to 13 - 17

N⋅m (9.4 - 12.3 ft. lbs.).
4. Connect the fuel inlet line.
5. Connect the fuel injection lines.
6. Connect the fuel return line to the number three 1
injector (three cylinder engines) or number four
injector (four-cylinder engines).
7. Spill-time the pump. 24
10-20
Spill-Timing Procedure
3
1. Remove the valve cover, 1, from the top of the en-
gine, by loosening bolts, 2, and cap nuts, 3.
2. Find top dead center of the No. 1 cylinder (No. 1 2
cylinder is the closest to the engine fan). No. 1 1
cylinder must be on the compression stroke. (In-
take and exhaust rocker arms will be loose.)
10044353
25
3. Remove the rocker arm housing and rocker arm

assembly, 1, from the engine.
1
10044354
26
4. Remove the keepers and spring from No. 1 cylin-

der intake valve, 1. 1
27
10-21
5. To verify true top dead center of piston travel,
install a dial indicator, 2, on the valve stem (No. 2
1 cylinder), 1. Be sure the valve stem is sitting
on top of the piston. Rotate the crankshaft until
the indicator needle reverses direction. The point 1
the needle reverses direction is true top dead
center.
28
6. Verify that the timing mark on the crankshaft
pulley is in line with the “TOP” mark on the timing
scale. If the mark on the crankshaft pulley is not
in line with the “TOP” mark, verify piston top dead
center by repeating step 5. If the pulley mark is
slightly off, remark the pulley and proceed.
NOTE: Color the timing mark on the crankshaft
pulley and appropriate marks on the timing scale to
increase visibility.
7. Reinstall the valve spring, keepers, rocker arm

assembly, housing and valve cover.
8. Shut off the fuel supply to the injection pump at
the fuel filter. 29
9. Remove the No. 1 injection line from the number

1 injector, 1.
1
30
10-22
10. Remove only the delivery valve piston, 1, from
the No. 1 delivery valve.
31
11. Reinstall the holder, 1, with spring into the injec-
tion pump and tighten securely. Insert a small di-
ameter wire down through the holder, 1, and
bend a hook on the end of the wire to hold the
spring, washer, and the valve in the holder, while
re-installing in the injection pump. Remove the
wire just prior to the holder being seated in the
pump.
32
NOTE: A remote fuel supply and fuel line must be
used to check spill timing. The fuel tank on the tractor 1
and the mechanical fuel pump will not allow free grav-
ity flow of fuel to the injection pump. Fabricate fuel
tank locally.
12. Use a remote fuel tank, 1, and fuel line, 2, for the
spill timing. Disconnect the fuel supply line at the
injection pump, 3.
13. Connect the remote fuel line, 2, to the injection
pump, 3. Put fuel in the remote tank, 1, and turn 2
on the fuel shutoff on the remote tank. 3
30002460
14. Place the throttle control lever in the full throttle
position. 33
15. Remove the fuel shut-off solenoid to verify the

control rack is positioned to the flywheel side.
10-23
16. Fabricate a spill tube, 1, from a discarded injec-
tion line and install the tube on the No. 1 port on
the injection pump.
17. The fuel shut-off solenoid has to be removed
from the injection pump, if installed. 1
34
18. Rotate the crankshaft counterclockwise (viewed
from the front of the engine) approximately 40°.
19. Turn on the fuel supply to the injection pump.
Fuel should flow out of the spill tube on the No.
1 cylinder port.
40°
35
20. Rotate the crankshaft clockwise. When the tim- 19°-21°
ing mark on the crankshaft pulley is in line with 17°-19°
the below degree marks on the scale, fuel should
stop flowing from the spill tube.
Engine Model Degree

N843L/D35, DX35 17 - 19° BTDC
N844/D40, DX40 19 - 21° BTDC
N844L, D45, DX45 17 - 19° BTDC
* BTDC - Before Top Dead Center
36
10-24
21. If fuel does not stop flowing at the appropriate
timing mark, the injection pump timing must be
adjusted by adding or removing shims located
between the injection pump and the engine
block.
22. Adding shims will retard the pump timing and re- 3
moving shims will advance the pump timing.
NOTE: A shim thickness of 0.1 mm (0.004″) will
change the pump timing by approximately 1°.
23. Assemble all components that were removed 1

from the engine and fuel system. 2
24. Disconnect the remote fuel line and tank, and re- 37
connect the fuel supply line to the injection pump.
FUEL SCREW/HIGH IDLE

Adjustment
The correct adjustment is required to reset to the
original production setting to ensure the engine will
be within the certified emission limits.
NOTE: EPA engine is certified to EPA emission legis-

lation.
No one is permitted to adjust the fuel flow rate more

than the max figure of submitting for power setting.
30002882
Adjustment only made by Case IH Area Service Man-
agers, due to EPA emission regulations. 38
Contact Case IH representative for adjustment of

fuel setting on high speed idle.
10-25
FUEL FLOW CHART
Return line to fuel tank
FUEL FUEL LIFT INJECTION

TANK FILTER PUMP PUMP
Return to
injection
pump
INJECTORS CYLINDERS
(3 or 4 cylinders)
20044364
39
FUEL PUMP 3. With the engine cranking, the fuel transfer pump,
which is activated by the engine camshaft rotat-
Auto Bleed ing, will deliver fuel to the injection pump.
With a full tank of fuel, fuel from the tank will push air
out of the fuel filter through the return to tank line. 4. Air that was in the injection pump will be returned
Fuel from the fuel filter will be delivered to the fuel to the fuel tank via the injector fuel return to tank
transfer pump. line.
NOTE: the injector fuel return to tank line is con-
The Auto Bleed occurs whenever the engine is nected to the fuel filter return to tank line.
started and the throttle is set at full throttle.
5. Rotate the engine until it starts.
1. Set the hand throttle at full throttle position.
NOTE: Due to heat generation in the starter motor,
2. Place ignition switch in the start position. do not engage the starter for more than 30 seconds
continuously.
10-26
Op. 10 230
GOVERNOR
The governor assembly is mounted on the forward
end of the camshaft.
20000730
40
1. Timing Gear Cover 7. Spring Holder
2. Lever 8. Washer
3. Arm 9. Spring
4. Lever 10. Spring
5. Arm Assembly 11. Stay
6. Shaft
As the engine speed increases, the throttle arm, 1,

contacts the fuel screw adjuster at contact point “A” 2
and the high-speed idle stop screw at “B”. During the A 1
engine speed increase, tension is placed on the gov-
ernor spring, 2.
41
As the engine speed increases the four governor
weights, 1, pivot outward and push the slider cone, 1
2. The weights and the slider cone are located on the
end of the camshaft.
1 2
10044355
42
10-27
The slider cone, contacts the governor linkage arm,
1, at contact pad “C”. As the cone moves forward it
pushes the linkage arm, 1, forward, which is con-
nected to the injection pump rack assembly. When 1
the injection pump rack moves forward the fuel deliv-
ery is decreased and the engine speed decreases.
43
As the engine speed decreases the governor
weights, 1, pivot inward allowing the slider cone, 2, 1
to move rearward.
1 2
10044355
44
As the slider cone moves rearward, the governor
linkage arm, 1, allows the fuel injection pump rack to
move rearward to the full fuel position and the engine
speed increases. 1
Engine speed depends upon several factors. The
throttle setting determined by governor spring ten-
sion. The pressure exerted by the slider cone on the
governor linkage, and positioning of the injection
pump rack.
All governor linkage parts are located inside the tim-

ing gear cover. To inspect or replace any of the gover-
nor linkage parts, the timing gear case and the injec-
tion pump must be removed from the engine as 45
discussed earlier in this section.
10-28
12
15
11
3
6
4 14
5
7 13
9
10
16 8
46
1. Timing Gear Cover 7. Throttle Cable Stay 13. Spring Holder Arm
2. Throttle Lever 8. E Ring 14. Washer
3. Throttle Arm 9. Pivot Shaft 15. E Ring
4. E Ring 10. O ring 16. Spring
5. Governor Spring 11. Linkage Arm Assembly
6. O ring 12. Dampener Spring
Disassembly 5. Remove E ring, 8, from the outside end of linkage

pivot shaft, 9. Pull pivot shaft, 9, out of the timing
1. Remove the injection pump and timing gear case
case. Inspect O ring, 10, on shaft. Replace if
from the engine as discussed earlier in this sec-
damaged.
tion.
6. Remove linkage arm assembly, 11, from the tim-
2. Remove the timing case, 1, from the front of the
ing case, 1. Remove governor spring, 5, and
engine. Remove the throttle lever, 2, from the
dampener spring, 12, from the linkage. Check all
outside end of throttle arm, 3.
pivot points, slot, and pin locations for wear. Re-
3. Remove the E ring, 4, from throttle arm, 3. Push place the linkage assembly, 11, if wear is present.
throttle arm into the timing case until there is Check spring holder arm, 13, making sure it piv-
enough space to remove governor spring, 5. Re- ots freely. Confirm that spacer, 14, is installed be-
move governor spring, 5, from throttle arm, 3. Re- tween arm and arm base. Also make sure the E
move throttle arm from timing case. Inspect O ring, ring, 15, is installed in the groove of the spring
6, and replace if damaged. holder arm.
4. Remove throttle cable stay, 7, from timing gear
cover, 1.
10-29
12
15
11
3
6
4 14
5
7 13
9
10
16 8
47
1. Timing Gear Cover 7. Throttle Cable Stay 13. Spring Holder Arm
2. Throttle Lever 8. E Ring 14. Washer
3. Throttle Arm 9. Pivot Shaft 15. E Ring
4. E Ring 10. O ring 16. Spring
5. Governor Spring 11. Linkage Arm Assembly
6. O ring 12. Dampener Spring
Assembly
NOTE: Align pin, “A”, with oil pump cover when the
case is assembled onto the engine.
1. Install governor spring, 5, onto linkage arm as-

sembly, 3. A
NOTE: Spring is installed onto front spring holder
arm with spring inserted from the inside of the arm.
48
10-30
2. Place linkage arm assembly, 11, into case.
NOTE: Check that spacer washer, 14, is installed be-
tween spring holder arm and base and E ring, 15, is
installed into groove of spring holder arm, 13.
The shaft is oriented with tapered end towards

outside of case. With O ring, 10, installed and the
shaft lubricated, insert pivot shaft, 9, into case.
Install shaft through linkage arm assembly, 11,
until O ring is in the case, 1. Install E ring, 8, onto
shaft, then push shaft into case until E ring
touches case.
3. Install throttle arm, 3, with O ring, 6, from the in-
side of the case, until the O ring engages into the
case. Install other end of governor spring, 5, into
the slotted hole of the throttle arm. Once the
spring is installed, push the rest of the throttle
arm into the case. Insert E ring, 4, into the groove
of the throttle arm.
4. Install the throttle cable stay, 7, onto the timing
gear cover, 1. Install throttle lever, 2, onto throttle
arm, 3. Align the slot “A” in the throttle lever with
groove “B” of the throttle arm. Retain lever to arm
by tightening clamp bolt and nut. After the clamp
bolt is tightened, pivot throttle lever back and
forth to check if all the linkage pivots freely. Install
throttle return spring, 16, to throttle lever, 2, and 2
stay, 7.
NOTE: The aligning of the slot in the lever with the
B
groove in the arm properly indexes the lever and at-
taching cables to the internal linkage. 3
A
5. Install the dampener spring, 12, onto linkage arm 49
assembly and timing case. The long leg of the
spring is inserted into the timing case.
NOTE: When installing timing case onto engine
block, make sure dampener spring stays in retaining
hole of case. Also, have the manual shutoff lever lo-
cated on the backside of the linkage arm assembly.
6. Check that nose cone, 1, slides freely on the end
of camshaft and guide pin. Lubricate nose cone
with never seize compound. 1
10044355
50
10-31
Adjustments
The governor assembly is mounted on the forward
end of the engine block. To remove and install the
governor assembly, see “Engine Timing Gear Cover,
Timing Gears and Cam Shaft”, discussed in chapter
1, Engine.
If the governor linkage has been disassembled, re- 1

assemble the linkage in the timing gear cover as dis-
3
1. Adjust the governor lever, 1, by aligning the slot, 2
4, in the lever with the groove, 3, in the governor 4
arm, 2.
51
10-32
Op. 10 218
INJECTORS 1
Throttle-type injectors are used in all engine applica-
tions. The injectors have a 1.0 mm (0.040″) single ori- 2
fice and are set at 146 bar (2150 psi). The pressure
adjustment is made by adding or deleting shims from 3
the top of the injector pressure adjusting spring. The
injectors have an injection angle of 4°. The injector 4
pipes are of the same length for each cylinder to help
keep the injection intervals in time. 5
The engine injection function is to inject fuel into a 6
pressurized cylinder in a fully atomized condition,
which provides efficient combustion with minimum 7
amount of smoke. Each injector assembly consists of 8
a nozzle assembly containing a needle valve, a
nozzle holder assembly, and injector needle valve
regulating spring. 9
52
1. Nut
2. Nipple Joint
3. Body
4. Shim
5. Spring
6. Push Rod
7. Distance Piece
8. Nozzle Nut
9. Nozzle Assembly
Fuel from the injection pump enters the injector inlet

and passes down through a drilling in the nozzle
holder and body to the needle valve seat. The fuel
pressurized by the injection pump, lifts the needle
valve off the seat against the action of the spring
pressure. The fuel is then forced, in the atomized
state, through the 1.0 mm (0.040″) orifice in the
nozzle tip. When pressure from the injection pump
drops, the needle valve snaps back onto its seat un-
der pressure from the spring.
To provide lubrication of the injector, a small amount

of fuel is permitted to leak up between the needle
valve and the nozzle body. The excess fuel rises to
the top of the injector and returns to the fuel tank 53
through the injection leak-offline. A. Nozzle Closed
B. Nozzle Initial Opening
C. Nozzle Fully Opened
10-33
Removal
1
1. Clean all dirt, oil, and grease from the injectors,
1, and surrounding areas.
2. Disconnect the fuel leak-off lines, 3, and injector
lines, 2, from the injectors.
54
3. Remove the injectors, 1, and sealing washers, 2,
from the cylinder head.
55
10-34
Disassembly
1
1. Loosen and remove the nozzle nut, 10, from the
injector body, 4, being careful not to drop or dam- 2
age the nozzle.
2. Remove the nozzle assembly, 9, spacer, 8, 3
spring, 6, and shim (s), 5.
4
3. Clean the nozzle body and the needle valve.
Check the nozzle for any burn or score marks. 5
Check the needle seat for evidence of fuel leak-
age or carbon deposits. 6
4. Correct fuel leakage at the seat using a polishing 7
stick and polish the seat area. 8
5. Inspect the upper and lower contact surfaces of 9
the nozzle holder for a clean contact surface
area.
10
6. Check the contact area between the push rod
and spring seat.
56
Assembly/Adjustment 1. Nut
2. Leak-Off Line
NOTE: Clean all parts in clean fuel oil and assemble
3. Washer
while still wet.
4. Injector Body
5. Shims
1. Install the shim(s), 5, spring, 6, spacer, 8, and
6. Spring
nozzle assembly, 9, in the injector body, 4.
7. Rod
2. Install the nozzle nut, 10 and tighten to 39 - 44 N⋅m 8. Spacer
(29 - 33 ft. lbs.). 9. Nozzle Assembly
10. Nozzle Nut
3. Check and adjust the injector pressure setting
using injector tester No. (NH #FNH01721, CIH
#OEM1064), and adapter fitting No. 23622. Ad-
just the pressure setting to 146 bar (2150 psi).
10-35
50043786
57
ENGINE BREATHER VALVE
1. When the gas (created by combustion) passes
through the piston ring, the gas is called
“blow-by-gas”.
2. When the crankcase pressure is less than 25 mm
Aq., the valve closes and the blow-by-gas is
trapped in the crankcase.
3. The blow-by-gas flows into the oil mist separator
and when crankcase pressure increases to
approximately 25 mm Aq. the valve opens. The
valve opening allows blow-by-gas to pass into
the intake manifold and be burned with the
aspirated air.
4. Therefore, the pressure inside of the crankcase
must be maintained from 25 to 100 mm Aq. so
that the blow-by-gas can not be discharged into
the air.
5. EPA Tier 2 requires the internal breather systems
for all naturally aspirated engines except the
turbocharged engines.
10-36
The breather valve, 1, is located atop the head cover.
Under the breather valve housing, is a diaphragm,
that allows the engine to recirculate combustion 1
gases, when the crankcase pressure builds.
Removal
1. Remove the four screws, 2, and pull breather
valve, 1, from head cover.
2
50043783
58
The breather valve consists of the following: Cover,
1, Spring, 2, Spring Retainer, 3, Diaphragm, 4. 2 3
NOTE: The breather valve must be replaced as an

assembly, not by individual pieces.
1 4
50043784
59
Installation
1. Place breather valve, 1, onto head cover. Make
sure vent hole, 2, is toward the front of the tractor, 1
for easy access and fasten with four bolts, 3.
IMPORTANT: Always keep small vent hole, 2, free of
oil and other debris, as to allow the crankcase, to vent
2
properly.
50043783
60
10-37
TROUBLESHOOTING -- ENGINE BREATHER VALVE
Engine emitting a bluish smoke Excessive blow by gases of engine. Replace piston rings, hone cylinder
Possible worn piston rings or walls to seat new rings
scored cylinder walls
Engine breather valve is stuck in Replace engine breather valve

“OPEN” position. Valve diaphragm diaphragm
is damaged allowing valve not to
close
Oil mist separator mesh screens Replace oil mist separator mesh
allowing oil to enter intake manifold screens
damaged or missing separator
mesh screens
Engine seals leaking oil Excessive crankcase pressure. Inspect diaphragm for damage or
High pressure caused by breather contamination. Replace diaphragm
valve not opening if necessary
Vent hole in valve body plugged Remove valve body from engine
and clean vent hole
10-38
SECTION 18 -- CLUTCH -- CHAPTER 1
SECTION 18 - CLUTCH
Chapter 1 -- Clutch
CONTENTS

18 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bolt Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Separating the Tractor at the Clutch Housing/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
18 110 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
18 110 Clutch Related Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pilot Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Damper Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Flywheel Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Clutch Release Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Clutch Linkage Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
18 100 Cross Shaft Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
18-1

Pedal Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Maximum Travel Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
18-2
SPECIFICATIONS
CLUTCH PLATES D35/D40 D45

Facing:
Outside Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 mm (9.4 in.) . . . . . . . . . . 260 mm (10.24 in.)
Inside Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 mm (6.3 in.) . . . . . . . . . . 170 mm (6.69 in.)
Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5 mm (0.1378 in.) . . . . . . . 3.5 mm (0.1378 in.)
Clearance between driveshaft and clutch disc . . . 0.2 -- 0.35 mm . . . . . . . . . . . 0.2 -- 0.35 mm
(.0078 -- .0137 in.) . . . . . . . . (.0078 -- .0137 in.)
Allowable Clearance Limit . . . . . . . . . . . . . . . . . . . . .0236 in. (0.6 mm) . . . . . . . . .0236 in. (0.6 mm)
Clearance between drive shaft And clutch

disc in the Rotation direction . . . . . . . . . . . . . . . . . . 0.050 -- 0.1 mm . . . . . . . . . . 0.050 -- 0.1 mm
(.0019 -- .0039 in.) . . . . . . . . (.0019 -- .0039 in.)
Allowable Clearance Limit Clearance . . . . . . . . . . 0.25 mm (.0098) . . . . . . . . . . 0.25 mm (.0098)

between retainer and release hub . . . . . . . . . . . . . . 0.025 -- 0.1 mm . . . . . . . . . . 0.025 -- 0.1 mm
(.0009 -- .0039 in.) . . . . . . . . (.0009 -- .0039 in.)
Allowable Clearance Limit . . . . . . . . . . . . . . . . . . . . 0.8 mm . . . . . . . . . . . . . . . . . 0.8 mm

(.314 in.) . . . . . . . . . . . . . . . . (.314 in.)
Length of release hub Return spring . . . . . . . . . . . . 35 mm . . . . . . . . . . . . . . . . . . 35 mm

(1.38 in.) . . . . . . . . . . . . . . . . (1.38 in.)
Thickness of clutch disc . . . . . . . . . . . . . . . . . . . . . . 8.0 mm . . . . . . . . . . . . . . . . . 8.0 mm

(.315 in.) . . . . . . . . . . . . . . . . (.315 in.)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 mm . . . . . . . . . . . . . . . . . 6.9 mm

(.27 in.) . . . . . . . . . . . . . . . . . (.27 in.)
Depth of clutch disc rivets . . . . . . . . . . . . . . . . . . . . 1.3 -- 2.0 mm . . . . . . . . . . . . . 1.3 -- 2.0 mm

(.0512 -- 0.0787 in.) . . . . . . . (.0512 -- 0.0787 in.)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm . . . . . . . . . . . . . . . . . 0.5 mm

(.02 in.) . . . . . . . . . . . . . . . . . (.02 in.)
Deflection of clutch disc . . . . . . . . . . . . . . . . . . . . . . 0.7 mm . . . . . . . . . . . . . . . . . 0.7 mm

(Max. .0276 in.) . . . . . . . . . . (Max. .0276 in.)
Standard Clutch Pedal Free-Play . . . . . . . . . . . . . . 19 -- 30 mm . . . . . . . . . . . . . . 19 -- 30 mm

(3/4 in. -- 1-3/16 in.) . . . . . . . (3/4 in. -- 1-3/16 in.)
Max. Allowable Free-Play . . . . . . . . . . . . . . . . . . . . . 30 mm . . . . . . . . . . . . . . . . . . 30 mm

(1-3/16 in.) . . . . . . . . . . . . . . (1-3/16 in.)
Standard Flywheel Thickness . . . . . . . . . . . . . . . . . 67 mm . . . . . . . . . . . . . . . . . . 65.3 mm

(2.64 in.) . . . . . . . . . . . . . . . . (2.57 in.)
Max. Allowable Flywheel Surface Removal . . . . . . 1.27 mm . . . . . . . . . . . . . . . . 1.27 mm

(0.050 in.) . . . . . . . . . . . . . . . (0.050 in.)
18-3
BOLT TORQUES
Flywheel Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 -- 78 N⋅m (50.6 -- 57.8 ft. lb.)
Clutch Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 -- 28 N⋅m (16 -- 21 ft. lb.)
SPECIAL TOOLS
Clutch Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #CNH299006, CIH #CAS2786)
30002394
18-4
The D35, D40 and D45 tractors are equipped with a

standard single clutch with the 12 x 12 Synchronized
Shuttle Shift transmission.
The clutch assembly consists of the clutch pressure
plate, 1, clutch disc, 2, flywheel, 3, release bearing,
4, return spring, 5, and the hub, 6. 1
3
The clutch disc is a dry organic type assembly, which 4
is mechanically operated. The clutch disc is installed 5
between the flywheel and pressure plate assembly.
The clutch pressure plate is attached to the flywheel
with six bolts on the D45, and nine bolts on the D35
and D40.
In the engaged position, the spring loaded pressure

plate presses the clutch disc into contact with the
engine flywheel. The power flow from the engine is
transmitted to the transmission by the friction 2
between the clutch disc linings and the surfaces of
the flywheel and the clutch pressure plate.
20002385
18-5
The clutch pedal, 1, is connected by an adjustable
rod, 2, to a bellcrank, 3, and cross shaft assembly, 4,
on which a fork is mounted.
The fork engages a sliding release bearing hub 3

assembly. When the clutch pedal is applied, the
2
release bearing comes in contact with the ends of the
clutch release levers in the pressure plate.
Depressing the clutch pedal causes the cross shaft
and fork to move the release bearing forward and
depress the pressure plate diaphragm spring. This 1
action draws the pressure plate away from the clutch
disc, releasing the disc from contact with the 10998241 4
flywheel.
3
The friction drive from the engine is then
disconnected to enable gear changes to take place.
After a gear change is made, and the clutch pedal is

released, the release bearing and hub are returned
to the free position by a spring attached to a hanger.
The diaphragm spring of the pressure plate

assembly then re-asserts pressure on the plate
moving it forward to press the clutch disc into contact
with the flywheel and re-establish the drive to the
transmission.
The release bearing is pre-lubricated and never

requires greasing.
The pressure plate assembly is not repairable and

must be replaced as a complete assembly if service
is required.
18-6
TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION

Excessive clutch pedal free play Worn clutch disc. Replace disc. Refer to “Clutch
or loss of adjustment reserve. Overhaul.”
Clutch linkage out of adjustment.
Adjust linkage. Refer to “Adjust-
ments.”
Clutch noisy when free. Defective release bearing. Replace bearing.
Defective clutch pilot bearing. Replace bearing.

Clutch slipping. Incorrect pedal free travel. Replace bearing.
Worn disc facings. Replace bearing.
Clutch pressure springs weak from

overheating.
Clutch fails to engage smoothly. Defective clutch disc. Replace disc. Refer to “Clutch
Overhaul.”
Defective pressure plate assembly.
Replace pressure plate assembly.
Worn clutch pilot bearing. Refer to “Clutch Overhaul.”
Defective flywheel. Replace bearing.
Refer to Sect. 10, “Engine System”

for removal and installation.
Difficulty in engaging gears. Pedal free travel out of adjustment. Refer to “Adjustments” to adjust the
pedal free travel.
Damaged or out of adjustment
release levers. Adjust assembly. Refer to “Adjust-
ments.”
Pedal will not return completely Broken clutch pedal return spring. Install a new spring.
to release position.
18-7
OVERHAUL
CLUTCH HOUSING/ENGINE
Removal
1 2
2. Drain all of the hydraulic fluid from the

transmission and the differential into a suitable
container.

remove the hood from the tractor. 30997558
4. Remove the seat, and the seat base assembly 4

from the tractor.

ROPS.

the right fender.

tractor.
30997555
5
panels.

the foot throttle control pedal, located on the right
deck.
10. Remove the left and the right deck from the 2
tractor. 1
10000864
6
18-8
12. Loosen and remove the two instrument panel
retaining screws, 1. Remove the instrument 2
1 3
panel, 2, from the dash housing, 3. Disconnect 1
the wiring connector from the instrument panel.
10998361
7
main shift bracket, 7, and the shuttle shift
bracket, 8, to the steering column, 9. Remove the
shift shaft assemblies by feeding the control
levers down through the dash housing.
14. Remove the dash housing from the firewall. 9

Disconnect the wiring connectors from the dash 6
8 7
switches. 6
2
4 5
1
3
10996566
8
2
1
20000908
9
18-9
the hydraulic pump, 2. 2
18. Remove the hydraulic system pressure tube, 3, 1
valve.
3
30997557
10
19. Disconnect the wires, 1, on the starter, 2, and
remove the starter from the tractor.
2
30997565
1
11


1
20000904
12
18-10
23. Drain the fuel tank into a suitable container.
1
2
3
10000865
13
and 3, on the engine. 1 1
2 3
10000867
14

2
10000868
15
18-11
raised or lowered to allow the separation of the
engine from the clutch housing.
28. Carefully roll the drive train away from the

engine, using the floor jack for support.
1
3
2
20000905
16
29. Remove the clutch rod, 1, from the clutch arm, 2,
located on the left side of the clutch housing.
1
2
10998241
17
30. Remove the range selector link, 1, from the
control arm, 2, on the transmission.
20000907 1
18
18-12
1
5
4
20000906
19
31. Remove the right brake rod, 1, from the brake
pedals, 2.
32. Remove the left brake rod, 3, from the clutch

pedal linkage, 4.
33. Remove the brake/clutch pedal assembly, 5,

from the transmission housing.
18-13
Op. 18 110
CLUTCH
Removal
The single clutch is serviced as a complete assembly
only. Overhaul of the single clutch is limited to
resurfacing the flywheel, and replacement of the
clutch assembly.
NOTE: Loosen the pressure plate retaining bolts
gradually and evenly to prevent distorting the 3
pressure plate assembly.
1. Remove the pressure plate retaining bolts, 1, and

remove the clutch assembly from the flywheel.
2. Remove the clutch disc, 2, from the pressure
plate, 3.
1
2
20002386
20
Inspection
1. Inspect the pressure plate face for scoring,
cracks, or signs of overheating. Minor imperfec-
tions may be removed by resurfacing the
pressure plate face. Replace the pressure plate
if damaged.
2. Inspect the diaphragm spring for wear or
damage.
3. Inspect the clutch disc lining for excessive wear.
Replace the clutch disc if the lining is worn to less
than 6.9 mm (.27 in.) on the D35 and D40, and
7.2 mm (.28 in.) on the D45, from the top of the
rivet head.
4. Inspect the clutch disc lining for indications of
overheating, scoring, or oil impregnation in the
lining. If any damage is present on the clutch
disc, replace with a new clutch disc assembly.
5. Inspect the hub spline for excess wear.
6. Inspect the cushioning springs for signs of wear
or damage.
18-14
Op. 18 110
Assembly
IMPORTANT: When installing a new pressure plate
assembly, the pressure plate friction surface must be
wiped clean with a suitable solvent to remove the
protective film.
1. Lightly lubricate the hub splines of the

transmission input shaft with a high temperature
lubricant.
2. Use the special tool No. (NH #CNH 299006, CIH
#CAS2786) Clutch Alignment Arbor, 1, to
position the clutch disc, 2, onto the flywheel, 3.
2
3
1
30002388
21
3. Install the pressure plate, 1, over the clutch
alignment arbor, 2, and align the mounting holes. 1
4. Install the retaining bolts to secure the pressure
plate to the flywheel.
2
30002389
22
IMPORTANT: Tighten the pressure plate retaining
bolts evenly and gradually to prevent distorting the
pressure plate assembly.
5. Install, tighten, and torque the retaining bolts, 1,

to 22 -- 28 N⋅m (16 -- 21 ft. lbs.).
20002386
23
18-15
1
5
4
20000906
24
ATTACHING THE 12 X 12 TRANSMISSION
TO THE ENGINE
WARNING
1. Install the brake/clutch pedal assembly, 5, onto

the transmission housing.
2. Attach the left brake rod, 3, to the clutch pedal

linkage, 4.
3. Connect the right brake rod, 1, to the brake

pedals, 2.
18-16
4. Attach the range selector link, 1, to the control
arm, 2, on the transmission.
20000907 1
25
5. Attach the clutch rod, 1, to the clutch arm, 2, on
the clutch housing.

the engine. Align the splines on the 12 x 12 input 1
shaft with the clutch and the engine flywheel. 2
Rotate the engine fan to align the input shaft and
the clutch/flywheel. The floor jack or the hoist
may need to be raised or lowered to make
alignment possible.
10998241
26
and nuts to 43.4 -- 55.6 N⋅m (32 -- 41 ft. Ibs.). Torque
the two M12 bolts to 81 N⋅m (60 ft. Ibs.).
1
3
2
20000905
27
18-17
the tractor.
10000868
28
9. Connect the fuel supply line, 1, to the fuel filter,
3, and connect the fuel tank return line, 2, to the
tee fitting.
1
2
3
10000865
29
and the clutch housing, 3. Secure with the
retaining bolts.
2
1
20000908
30
18-18
11. If equipped, Install the FWD driveshaft, 2, and
secure with the two roll pins, 1.
1
20000904
31
the starter, 2. 2
30997565
1
32
the hydraulic pump, 2, and the diverter valve. 2
14. Install the hydraulic system inlet tube, 1, onto the 1
hydraulic pump, 2.
15. Connect the main wiring harness connector.
17. Connect the throttle cable to the foot throttle

control lever located on the right deck.
18. Install the left and right fenders on the tractor. 3

30997557
19. Install the seat and the seat base on the tractor. 33
ROPS.
18-19
valve, 1, on the right fender. Connect the
hydraulic tubes.
23. Connect the wiring connectors to the dash

housing switches.

throttle control lever. 1
30997555
34
instrument panel. Install the instrument panel, 2, 2
1 3
into the dash housing, 3, and secure with two 1
screws, 1.
10998361
35
bracket, 8, to the steering column, 9, with the
retaining bolts, 6. Connect the lower main shift
shaft, 5, and shuttle shift shaft, 2, to the
transmission shafts with the roll pins, 4 and 1,
and retaining ring, 3.
27. Install the hood on the tractor and connect the 9

headlight wiring connector. 6 8 7 6
2
4 5
1
3
10996566
36
18-20
panels.
29. Fill the hydraulic reservoir with Ambra Multi G

134 Hydraulic Fluid, to the proper level.

tractor. 2
1
removed during disassembly, install a new oil
filter on the engine, and fill the engine with the
recommended oil to the proper level.
10000864
37
1 2
33. Make any adjustments necessary for proper
operation of the tractor.
30997558
38
18-21
Op. 18 110
CLUTCH RELATED COMPONENTS

PILOT BEARING
A pre-lubricated pilot bearing is installed at the rear
of the engine to support the front end of the 1
transmission input shaft. The pilot bearing, 1, is 2
located in the flywheel, 2.
Whenever the clutch has been removed, inspect the

pilot bearing by turning the inner race by hand and
observe for abnormal noise, uneven rotation or
excessive free-play.
Removal
1. If damage or wear is apparent, remove the pilot
bearing using a suitable puller. 20002386
39
Installation
1. Apply a few drops of sealer to the outer race and
install the new pilot bearing using a suitable size
driver.
2. Be sure that the driver only contacts the outer
race so as not to damage the bearing during
installation.
3. Be sure that the bearing sealed side is installed
facing toward the clutch, and bottoms against the
shoulder in the flywheel.
DAMPER DISC
The damper disc is used to dampen vibration from
the flywheel, and the clutch, and cushion engage-
ment of the PTO clutch and the transmission clutch.
The damper disc is bolted to the engine flywheel, and
has a splined center to which the PTO driveshaft is
connected. The damper disc mounted to the
flywheel, is used to transmit power from the engine,
through the PTO driveshaft, into the PTO clutch
located in the differential housing. The damper disc
has cushioning springs mounted on its face to
cushion the power delivery from the damper disc to
the PTO clutch. This allows smoother clutch
engagement, while reducing fatigue on clutch related
parts due to vibration and sudden engagement. The
D35, D40 and D45 single clutch uses a damper disc
on the clutch disc as well as on the flywheel.
18-22
Removal
1. Loosen and remove the eight retaining bolts, 1,
that secure the damper disc, 2, to the flywheel, 3.
2
2. Remove the damper disc, 2, from the flywheel, 3.
Inspection
1. Clean the damper disc in a suitable solvent, and
allow to air dry. 3
2. Check the cushioning springs for weakness or
damage. Replace as necessary.
1
3. Check the damper disc for cracks or other 20002437
damage. Replace as necessary. 40
Installation
1. Install the damper disc onto the flywheel, using the 1
clutch alignment arbor, tool (NH #CNH299006,
CIH #CAS2786), 1.
NOTE: Tighten the damper disc bolts in a criss-cross
pattern to evenly secure the disc to the flywheel.
30002394
41
2. Install and tighten the eight retaining bolts, 1,
through the damper disc, 2, and into the flywheel,
3. Torque the bolts, 1, to 13.7 N⋅m (10 ft. lbs.).
2
1
20002437
42
18-23
C
E
B
A
50043893
43
FLYWHEEL DIMENSIONS
Tractor A B C D E
D35 300 mm 42 mm 22.3 mm 67.0 mm 0.3 mm
(11.81 in.) (1.65 in.) (0.88 in.) (2.64 in.) (0.012 in.)
D40 300 mm 42 mm 22.3 mm 67.0 mm 0.3 mm
(11.81 in.) (1.65 in.) (0.88 in.) (2.64 in.) (0.012 in.)
D45 318 mm 52 mm 25.8 mm 65.3 mm 0.8 mm
(12.52 in.) (2.04 in.) (1.01 in.) (2.57 in.) (0.031 in.)
Maximum removal of flywheel clutch surface -- 1.27 mm (0.050 in.).
NOTE: When flywheel surface is reduced, dimension “E” must be kept to original specification.
18-24
CLUTCH RELEASE BEARING

6 4 3
The clutch release bearing, 1, is a pre-lubricated
bearing and is mounted on the sliding hub, 2, which
is supported on the front input shaft retainer, 3. A fork,
4, mounted on the cross shaft, 5, engages the
bearing and hub assembly.
5
Pushing on the clutch pedal causes the release
bearing, 1, to come in contact with the diaphragm
spring in the pressure plate. Continued pushing
causes the diaphragm spring to pull the pressure
plate away from the clutch disc, disengaging the 2
clutch, and the drive to the transmission input shaft, 20002387 1
stopping the transmission.
44
Removal
1. Separate the tractor between the engine and the
clutch housing. See “Separating the Tractor at
the Clutch Housing/Engine”, earlier in this
section.
2. Remove the cotter pin and the clevis pin, 1, from
the adjustment rod, 2, at the clutch release cross 1
shaft, 3.
3 2
10998241
45
3. Remove the hub return spring, 6, and slide the
bearing, 1, and the hub, 2, off the input shaft, 3. 6 4 3
4. Use a suitable puller to remove the bearing, 1,
from the hub, 2.
2
20002387 1
46
18-25
Inspection
1. Rotate the bearing by hand and check for
abnormal noise, uneven rotation, excessive
free-play, scoring and indications of lubricant
leakage at the oil seals.
2. If any damage or wear is detected, replace the
bearing.
Installation
6 4 3
1. Install a new release bearing, 1, onto the hub, 2,
using a suitable driver.
2. Install the bearing and hub, 2, onto the input
shaft, 3.
3. Connect the hub return spring, 6, to the hub, 2. 5
2
20002387 1
47
CLUTCH LINKAGE COMPONENTS

Op. 18 100
CROSS SHAFT BUSHINGS

Disassembly
1. Separate the tractor between the engine and the
clutch housing. See “Separating the Tractor at
the Clutch Housing/Engine”, earlier in this
section.
2. Remove the clutch rod, 1, from the clutch cross
shaft bellcrank, 2.
1
2
10998241
48
18-26
3. Remove the retaining ring, 1, from the cross
shaft, 2. 4
4. Remove the roll pin, 3, from the fork, 4, and the
cross shaft, 2, and remove the cross shaft from 1
the clutch housing.
5. Use a suitable driver, and remove the bushings 2
from the clutch housing.
3
20002387
49
Assembly
1. Use a suitable driver, and install new bushings in
the clutch housing.
2. Install the cross shaft, 2, through the clutch
housing and the fork, 4. Secure the fork, 4, with 4
the roll pin, 3.
3. Install the retaining ring, 1, onto the cross shaft, 1
2.
3
20002387
50
4. Attach the clutch rod, 1, to the clutch cross shaft
bellcrank, 2.
1
2
10998241
51
18-27
9
6 5
1 4
2
3
8
1
20002390
52
PEDAL BUSHINGS Assembly
Removal 1. Use a suitable driver to install the bushings on the
clutch pedal assembly.
1. Disconnect the brake actuating rods, 1, from the
brake cross shaft, 2, and the brake pedal, 6. Installation
2. Remove the roll pins, 3, from the brake cross 1. Install the clutch pedal, 7, onto the brake cross
shaft, 2. shaft, 2, and install the brake cross shaft, 2,
through the support, 8.
3. Remove the clutch pedal return spring, 4.
2. Install the clutch adjustment rod, 5, onto the
4. Remove the clutch adjustment rod, 5, from the
clutch pedal, 7.
clutch pedal, 7.
3. Install the clutch pedal return spring, 4.
5. Remove the brake cross shaft, 2, from the
support, and remove the pedal from the shaft. 4. Install the two brake pedals, 6 and 9, onto the
brake cross shaft, 2.
Disassembly 5. Install the roll pins, 3, into the brake cross shaft, 2.
1. Use a suitable driver to remove the bushings
6. Attach the brake actuating rods, 1, on the brake
from the clutch pedal assembly.
cross shaft, 2, and on the outside brake pedal, 6.
18-28
PEDAL ADJUSTMENT 19 mm-30 mm

Adjustment (3/4″-1-3/16″)
1
NOTE: Check clutch pedal free travel after every 50
hours of operation.
Clutch pedal free travel should be maintained at

19 mm -- 30 mm (3/4″ -- 1-3/16″).
To adjust the clutch pedal:
1. Loosen jam nuts, 1.

2
2. Lengthen the rod, 2, to decrease pedal free travel 10998241
or shorten to increase. 53
NOTE: Rod has right and left hand thread for ease of
adjustment. No need to disconnect clevis for
adjustment.
Maximum Travel Adjustment

The clutch pedal linkage has a mechanical stop, 3, to 1
prevent damage to the clutch components due to
over travel. Clutch pedal travel is measured between
the top surface of the pedal arm and the front up stop
plate, 1.
Maximum clutch pedal travel, 4, is set to: 79 to 89 mm 2

(3.125″ to 3.50″). To adjust, loosen jam nut, 2, and
increase bolt length, 3, to decrease pedal travel and 4
shorten bolt length, 3, to increase pedal travel.
3
NOTE: Measurement is taken at the steel surface of 19999207
stop and not the rubber pad.
54
18-29
18-30
SECTION 21 - TRANSMISSION - CHAPTER 1
CONTENTS

21 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cross Section -- 12 x 12 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Powerflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 114 Separating the Tractor at the Clutch Housing/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 110 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
21 148 63 Retainer Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
21 148 63 Main Shift Rails and Shift Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
21 148 63 Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
21 148 63 Range Shift Rail and Shift Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
21 148 63 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
21 148 63 Reverse Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
21 148 63 Shuttle Shift Rail and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
21 148 63 Main Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
21 148 63 Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
21-1

Main Transmission Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Synchronizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Main Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Shuttle Shift Rail and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Reverse Idler Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
21 148 63 Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
21 148 63 Main Countershaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
21 148 63 Range Shift Rail and Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
21 148 63 Main Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
21 148 63 Main Shaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
21 148 63 Main Shaft Gears End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Main Shift Rails and Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Retainer Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
21 110 10 Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
21 130 Transmission Shift Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Main Shift Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Main Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Shuttle Shift Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
21-2
SPECIFICATIONS
Synchronized Shuttle Shift Gear Transmission (12 x 12)
Maximum Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 mm (0.024″)
Clearance Between Synchronizer Sleeve and Shift Fork . . . . . . . . . . . . . . . . . . . . 0.2 - 0.4 mm (0.008 - 0.016″)
Allowable Clearance Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (0.039″)
Synchronizer Ring to Gear Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum 0.8 mm (0.031″)
Main Shaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . zero end float with no bearing preload
Main Shaft Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2, 0.5 mm (0.008, 0.020″)
Countershaft End Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . zero end float with no bearing preload
Countershaft Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1, 0.2, 0.5 mm (0.004, 0.008, 0.020″)
21-3
Bolt Grade Pitch Foot- Newton Pitch Foot- Newton-

Size No. (mm) Pounds Meters (mm) Pounds Meters
4T, 4.8 2.8 - 4.0 3.8 - 5.4
M5 7T, 8T, 8.8 0.70 4.9 - 6.9 6.9 - 9.3 ----------- ------------ ------------
10T, 10.9, 11T 6.7 - 9.4 9.0 - 12.7
4T, 4.8 3.6 - 5.1 4.9 - 6.9
M6 7T, 8T, 8.8 1.0 6.1 - 8.3 8.3 - 11.3 ----------- ------------ ------------
10T, 10.9, 11T 8.7 - 11.6 11.8 - 15.7
4T, 4.8 9.4 - 12.3 12.7 - 16.7 11.2 - 14.8 15.2 - 20.1
M8 7T, 8T, 8.8 1.25 16.6 - 21.0 22.6 - 28.4 1.0 19.5 - 25.3 26.5 - 34.3
10T, 10.9, 11T 21.0 - 26.8 28.4 - 36.2 22.4 - 29.7 30.4 - 40.2
4T, 4.8 18.8 - 24.6 25.5 - 33.3 21.0 - 26.8 28.4 - 36.3
M10 7T, 8T, 8.8 1.5 32.5 - 41.2 44.1 - 55.9 1.25 36.2 - 46.3 49.0 - 62.8
10T, 10.9, 11T 39.8 - 51.4 53.9 - 69.9 42.7 - 54.2 57.9 - 73.5
4T, 4.8 27.5 - 34.7 37.3 - 47.1 31.8 - 40.5 43.1 - 54.9
M12 7T, 8T, 8.8 1.75 48.5 - 61.5 65.7 - 83.4 1.25 55.0 - 69.4 74.5 - 94.1
10T, 10.9, 11T 68.0 - 85.4 92.9 - 116 73.1 - 93.3 99.0 - 127
4T, 4.8 46.3 - 59.3 62.8 - 80.4 51.4 - 64.4 69.6 - 87.3
M14 7T, 8T, 8.8 2.0 76.7 - 96.9 104 - 131 1.5 86.1 - 109 117 - 148
10T, 10.9, 11T 102 - 129 139 - 175 108 - 137 147 - 186
4T, 4.8 63.6 - 81.0 83.3 - 110 67.3 - 84.6 91.3 - 115
M16 7T, 8T, 8.8 2.0 110 - 136 149 - 184 1.5 116 - 142 157 - 192
10T, 10.9, 11T 152 - 188 206 - 255 163 - 199 221 - 270
4T, 4.8 106 - 132 144 - 179 127 - 156 172 - 211
M20 7T, 8T, 8.8 2.5 177 - 213 240 - 289 1.5 203 - 246 275 - 333
10T, 10.9, 11T 268 - 325 363 - 441 293 - 358 397 - 485
21-4
SPECIAL TOOLS
Detent ball retaining tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH# FNH00081, CIH #CAS2788
21-5
The Synchronized Shuttle Shift 12 x 12 transmission
provides 12 forward and 12 reverse speeds, which 2
are manually controlled by three shift levers. The
Synchronized Shuttle Shift transmission is driven by 1
a single disc clutch.
The shuttle shift lever, 1, controls forward and

reverse, while the main transmission shift lever, 2,
controls the four gear speeds in the main
transmission.
10035024
2
The range lever, 3, controls the three transmission
range gears.
30997548
3
21-6
The transmission case consists of three compart-
ments. The forward compartment, 1, contains the 3 2 1
forward and reverse shuttle transmission gears. The
shuttle gears are designed for synchronized shifting
and are controlled by a column mounted shift lever.
The center compartment, 2, contains the main

transmission gears consisting of four gear speeds.
These gears are designed for synchronized shifting
and are controlled by a column mounted shift lever.
The rear compartment, 3, contains the range gears

which provide three speed ratios for each of the main
transmission speeds for a total of 12 forward and 12
reverse speeds. The range gears are not synchro- 10996564
nized and are controlled by a lever located on the 4
floor, by the left side of the operator’s seat.
The shuttle gears and main transmission gears are

in constant mesh. Shifting is accomplished by
engaging and disengaging three synchronizer
assemblies located in the front and center
transmission compartments.
The range gears are not synchronized. Shifting is

accomplished by engaging sliding gears located in
the rear transmission compartment
The transmission housing serves as a common fluid

reservoir for the final drive assembly, the transmis-
sion, and the hydraulic system. The fluid used is
Hy-Tran Ultra.
The fluid fill plug, 1, and the fluid level dipstick, 2, are
located on the top of the hydraulic lift cover. 2
21-7
11 12 13 14 15 16 17 18 19
4 5 6 7 8 9 10
3 2
10996560
CROSS SECTION - 12 x 12 TRANSMISSION

1. Shuttle gear (35T) 11. Fixed shuttle gear (30T)
2. Shuttle gear (34T) 12. Fixed shuttle gear (26T)
3. Reverse idler gear (26T) 13. Third gear (38T)
4. Fixed gear (22T) 14. Fourth gear(34T)
5. Fixed gear (26T) 15. First gear (44T)
6. Fixed gear (16T) 16. Second gear (41T)
7. Fixed gear (19T) 17. Fixed range gear (39T)
8. Sliding range gear (21T) 18. Fixed range gear (25T)
9. Sliding range gear (35T) 19. Fixed range gear (15T)
10. Fixed range gear (57T)
21-8
POWERFLOW
The transmission input shaft relays power to the
main countershaft by way of the synchronizers for
the forward and reverse gears. Power from the main
countershaft is relayed to the main shaft by the
synchronizers for first, second, third, and fourth
gears. The PTO shaft runs through the center of the
main shaft to relay power to the rear PTO. From the
main shaft, power proceeds to the rear of the
transmission by way of the range gears. These
consist of three fixed gears on the main shaft and two
sliding gears and one fixed gear on the countershaft.
21-9
21-10
21-11
21-12
TROUBLESHOOTING
Oil leakage 1. Hydraulic oil is over full 1. Adjust transmission oil level
2. Loose bolts 2. Retorque bolts
3. Worn oil seals or O rings 3. Replace seal or O ring
4. Defective or torn gaskets 4. Replace gasket
5. Cracked transmission housing 5. Replace the transmission
housing
Abnormal noise 1. Worn bearing 1. Inspect and replace

2. Excessive gear backlash 2. Adjust or replace
3. Worn gears 3. Replace
4. Gears improperly engaged 4. Adjust or replace
5. Oil level low 5. Adjust oil level
Gears will not engage 1. Clutch is not disengaged 1. Refer to section 4, “Clutch”
2. Damaged shift lever 2. Replace
3. Bent or damaged shift fork or 3. Repair or replace
shift rail
4. Top main shaft adjusting collar 4. Refer to “Main Shaft End Float”
adjusted too tight earlier in this section
Gears disengage 1. Damaged detent spring 1. Replace

2. Worn detent grooves on shift 2. Replace
rail
3. Uneven gear wear 3. Replace
4. Worn detent ball 4. Replace
Gears difficult to disengage 1. Bent shift rod 1. Replace

2. Foreign material in synchroniz- 2. Disassemble and clean
er
3. Clutch drags 3. Adjust clutch or replace
21-13
OVERHAUL
Op. 21 114
CLUTCH HOUSING/ENGINE
1 2
Op. 21 110 10
Removal
transmission and the differential into a suitable
container. 30997558
3. Disconnect the headlight wire harness plug and 10

4. Remove the seat, and the seat base assembly
from the tractor.
ROPS.

the right fender.
tractor.
30997555
11
panels.
the foot throttle control pedal, located on the right
deck.
10. Remove the left and the right deck from the
tractor. 2
1
10000864
12
21-14
retaining screws, 1. Remove the instrument 2 1
panel, 2, from the dash housing, 3. Disconnect
the wiring connector from the instrument panel. 1
10035024
13
main shift bracket, 7, and the shuttle shift
bracket, 8, to the steering column, 9. Remove the
shift shaft assemblies by feeding the control
levers down through the dash housing.
14. Remove the dash housing from the firewall.
Disconnect the wiring connectors from the dash 6 9
switches. 8 7 6
2
4 5
1
3
10996566
14
2
1
20000908
15
21-15
the hydraulic pump, 2. 2
valve.
3
30997557
16
remove the starter from the tractor.
2
30997565
1
17

1
20000904
18
21-16
1
2
3
10000865
19
and 3, on the engine. 1 1
2 3
10000867
20
2
10000868
21
21-17
engine from the clutch housing.

1
3
2
20000905
22
29. Remove the clutch rod, 1, from the clutch arm, 2,
located on the left side of the clutch housing.
1
2
10998241
23
30. Remove the range selector link, 1, from the
control arm, 2, on the transmission.
20000907 1
24
21-18
1
5
4
20000906
25
31. Remove the right brake rod, 1, from the brake
pedals, 2.
32. Remove the left brake rod, 3, from the clutch
pedal linkage, 4.
33. Remove the brake/clutch pedal assembly, 5,
21-19
CLUTCH HOUSING
Disassembly 1
2 3
1. Remove the clutch hub return spring, 1, from the
clutch hub, 2, and the retainer pin, 3.
10996562
26
2. Remove the retainer pin, 1, from the clutch
housing, 2.
1
10996426
27
3. Remove the clutch hub and bearing, 1, from the
input shaft, 2. 2
10996427
28
21-20
4. Loosen and remove the three bolts, 1, securing
the main gear selector shaft, 2, to the clutch
housing.
2
1
10996428
29
5. Remove the main gear selector shaft, 1, from the
clutch housing, 2.
10996429
30
6. Loosen and remove the three bolts, 1, securing
the shuttle gear selector shaft, 2, to the clutch
housing.
2
1
10996430
31
21-21
7. Remove the shuttle gear selector shaft, 1, from
the clutch housing, 2.
1
10996431
32
8. Loosen and remove the transmission cover
bolts, 1.
CAUTION
Use care when removing the transmission cover
from the transmission housing. The detent ball
and spring could be expelled with force when the
cover is removed.
9. Remove the transmission cover, 2, from the

transmission housing, 3. 3 1 2
10996432
33
10. Remove the spring, 1, and detent ball, 2, from the
main transmission gear detent hole, 3, in the
transmission housing. 1
3
10996433
34
21-22
11. Remove the pin, 1, spring, 2, and the detent ball,
3, from the shuttle shift detent hole in the
transmission housing.
1
3
10996434
35
12. Loosen and remove the bolt, 1, from the diverter
valve bracket and remove the hydraulic tubes, 2, 1
from the diverter valve, 3. Remove the diverter
valve, 3, and the hydraulic tubes, 2, from the 2
3
10996435
36
13. Loosen and remove the seven buckle-up bolts,
1, and the three buckle-up nuts, 2, that secure the
clutch housing to the transmission housing. 1
14. Remove the clutch housing from the transmis-
sion.
10996436
37
21-23
15. Use a hoist or other suitable lifting device to
support the transmission while loosening the
eight buckle-up bolts, 1, and two buckle-up nuts
that secure the transmission to the differential 1
housing.
16. Remove the bolts and nuts.
17. Separate the transmission housing from the
differential housing.
10996437
38
MAIN TRANSMISSION
2
Op. 21 148 63
RETAINER COVER
Disassembly
1. Remove the PTO shaft, 1, that is housed in the
main shaft, 2.
1
10996563
39
2. Loosen and remove the six bolts, 3, that secure
the retainer cover, 1, to the transmission housing. 1 2 3 4
Remove and discard the six seal washers, 4.
3. Remove the retainer cover, 1, and gasket, 2, from
the front of the transmission housing.
10996565
40
21-24
4. Remove and discard the input shaft seal, 1, from
the retainer cover, 2. 2
10996561
41
Op. 21 148 63
MAIN SHIFT RAILS AND SHIFT FORKS
Disassembly
1. Drive the roll pin out of the upper shift rail, 1, and
shift fork, 2. 1
2
10996438
42
2. Remove the upper shift rail, 1, and shift fork, 2,
1 2
10996439
43
21-25
3. Remove and discard the shift rail oil seal, 1, from
the transmission housing. 1
10996552
44
4. Drive the roll pin out of the lower shift rail, 1, and
shift fork, 2.
1
10996440
45
5. Use a pencil magnet, 1, to remove the balk pin,
2, from the detent hole, 3, in the transmission 1
housing.
10996441
46
21-26
6. Turn the lower shift rail, 1, 90° to ease removal
from the transmission case.
90°
10996442
47
CAUTION
Use care when removing the lower shift rail.
Cover the detent hole, 1, with a shop rag. The
detent ball and spring could be expelled with
force when the shift rail is removed.
10996558
48
7. Pull the lower shift rail, 1, from the shift fork, 2,
and the transmission housing.
2
8. Remove the shift fork, 2, from the transmission
housing.
1
10996444
49
21-27
9. Use a pencil magnet to remove the detent ball, 1,
and spring, 2, from the detent hole in the 1
transmission.
10996571
50
10. Remove and discard the shift rail oil seal, 1, from
10996552
51
Op. 21 148 63
1
MAIN SHAFT
Disassembly
1. Use a punch and a hammer and lightly tap the
rear bearing, 1, out of the transmission case
counterbore.
10996445
52
21-28
2. Pull the main shaft towards the back of the
transmission case, while sliding the front main
gear and synchronizer assembly, 1, off of the
main shaft. 1
3. Lift the front main gear and synchronizer
assembly, 1, from the transmission case. Keep
the gears and the synchronizer together as an
assembly.
10996446
53
4. Continue to pull the main shaft, 2, towards the
back of the transmission case, while sliding the
rear main gear and synchronizer assembly, 1, off 1
of the main shaft, 2.
5. Lift the rear main gear and synchronizer
assembly, 1, from the transmission case. Keep
the gears and the synchronizer together as an
assembly.
10996447
54
6. Continue to pull the main shaft, 1, to the rear
while removing the bearing, 2. 2
10996448
55
21-29
7. Remove the large range gear, 1, from the main
shaft, 2. 1
2
10996449
56
8. Remove the adjuster collar, 1, from the main
shaft, 2. 1
10996450
57
9. Remove the small range gear, 1, from the main
shaft, 2. 1
2
10. Remove the main shaft, 2, from the transmission
housing, 3.
3
10996451
58
21-30
Op. 21 148 63
RANGE SHIFT RAIL AND SHIFT FORK
Disassembly
1. Loosen and remove the shift rail retaining bolt
and seal washer from the side of the
10996528
59
2. Turn the shift rail, 1, 90° to free the shift rail, 1,
from the detent ball in the shift fork, 2.
2
1
90°
10996529
60
CAUTION
Use a shop towel over the hole in the shift fork to
keep the detent ball and spring from being
expelled with force while removing the shift rail.
3. Remove the shift rail, 1, from the shift fork, 2, by

pulling the rail out the back of the transmission
housing. Remove the shift fork, 2, from the
1
10996530
61
21-31
4. Remove the retaining bolt, 1, the locking plate, 2,
and the shift arm, 3, if any wear or damage is
discovered.
3
2
1
10996569
62
Op. 21 148 63
RANGE GEAR COUNTERSHAFT 2
1
Disassembly
1. Using a retaining ring pliers, slide the retaining
ring, 1, that secures the low range gear, 2,
forward on the countershaft, 3.
3
10996532
63
2. Work the countershaft, 1, rearward and out of the
transmission housing, while supporting the low
2
range gear, 2, and the sliding gear, 3.
3. Remove the sliding gear, 3, from the counter- 1
shaft, 1.
3
10996533
64
21-32
4. Remove and discard the retaining ring, 1, from
the countershaft, 2. 3
2 1
5. Remove the low range gear, 3, from the
countershaft, 2, and remove the countershaft
10996534
65
6. Remove the needle bearing, 1, from the end of
the main countershaft, 2. 2
10996535
66
Op. 21 148 63
INPUT SHAFT 2
1
Disassembly
1. Remove the input shaft rear bearing, 1, from the
bearing holder, 2.
2. Remove the bearing holder, 2, from the
counterbore.
10996536
67
21-33
3. Using an aluminum drift and a hammer, lightly tap
on the forward gear, 1, to loosen the input shaft,
2, from the remaining rear bearing.
10996537
68
4. With the input shaft loose from the bearing, pull
the input shaft, 1, with the reverse gear, 2, out of 3 2
the front of the transmission housing.
5. Remove the forward gear, 3, from the 1
6. Remove the remaining input shaft bearings from
10996538
69
Op. 21 148 63
REVERSE IDLER SHAFT
Disassembly
1. Drive the roll pin, 1, out of the reverse idler shaft,
2.
2
1
10996539
70
21-34
2. Loosen and remove the idler shaft retaining bolt,
1, from the side of the transmission case.
10996540
71
3. Push the idler shaft, 1, towards the front of the
transmission case.
4. Remove the thrust washer, 2, from the idler shaft, 2
1, taking note of the orientation of the oil channels
1
in the thrust washer.
10996541
72
5. Remove the reverse idler gear, 1, and the two
needle bearings, 2, from the idler shaft. 2 2
10996542
73
21-35
6. Remove the reverse idler shaft, 1, from the
2
7. Remove and discard the O ring, 2, on the end of 1
the idler shaft, 1.
10996543
74
Op. 21 148 63
SHUTTLE SHIFT RAIL AND FORK
1
Disassembly
2
1. Remove the neutral safety switch, 1, the seal
washer, 2, and balk pin, 3, from the transmission 3
housing.
10996544
75
2. Drive the double roll pin from the shift rail, 1, and
shift fork, 2.
2 1
10996545
76
21-36
3. Turn the shift rail, 1, 90° and remove from the shift
fork, 2, and the inside hole of the transmission
housing.
2 3
4. Remove the spacer, 3, from the shift rail, 1. 1
5. Remove the shift rail, 1, from the front of the 90°
10996546
77
6. Remove and discard the shift rail seal, 1, from the
1
10996547
78
Op. 21 148 63
MAIN COUNTERSHAFT 1
2
Disassembly
1. Straighten the peened tab, 1, on the countershaft
locknut, 2. Remove the locknut.
10996548
79
21-37
2. Using an aluminum drift and a hammer, tap the
countershaft loose towards the rear of the
10996549
80
3. Remove the front main countershaft bearing, 1,
from the counterbore in the transmission
housing.
1
10996550
81
4. Remove the collar, 1, through the bearing
counterbore.
10996551
82
21-38
5. Pull the countershaft, 1, to the rear of the
transmission housing, and carefully remove the 1
shuttle gears and synchronizer, 2, from the 3
6. Continue to pull the countershaft, 1, to the rear of
the transmission housing while removing the 2
fixed gears, 3.
7. Remove the countershaft, 1, from the back of the
83
Op. 21 148 63
5
SYNCHRONIZERS 4
Disassembly 3
The synchronizer assemblies can also be disas- 1
sembled if necessary. Be certain that the hubs and
sleeves have matching marks.
1. Synchronizer Hub
2. Synchronizer Sleeve
3. Retaining Ring
4. Inserts
4
5. Matching Marks
2
4
84
1. Place the synchronizer/gear assembly on the
workbench and insert the shift fork, 1, onto the
synchronizer sleeve, 2.
2. Use a feeler gauge, 3, to measure the side
clearance between the sleeve, 2, and the shift 1
fork, 1. See “Specifications” later in this section 2
for maximum clearance.
3
85
21-39
1. Place the synchronizer rings, 1, on the
synchronizer gears, 2, and use a feeler gauge, 3, 3 2
to measure the cone wear. See “Specifications”
later in this section for minimum clearance.
86
MAIN TRANSMISSION COMPONENTS
Inspection
1. Wash all components using a suitable cleaning
solvent and air dry.
2. Inspect all bearings for excess wear, score
marks, discoloration from overheating, or other
damage. Rotate the bearings by hand and check
for roughness while slowly rotating the inner and
outer races.
3. Lubricate all bearings with a clean lubricant,
Hy-Tran Ultra or equivalent, before installation.
4. Inspect the transmission housing for pitting,
cracks, worn bearing bores, or other damage.
5. Check the detent springs for wear, chipping, or
weak spring tension.
6. Inspect the detent balls for pitting, excess wear
or other damage.
7. Inspect the shift rail detent grooves for excess
wear or other damage.
8. Inspect all gears for excess wear, chipped teeth
or other damage.
SYNCHRONIZERS
4
Assembly 5
1. Place one of the retaining rings, 3, in the 1
synchronizer hub, 1. Position the end of the ring 3
in the hole in the hub.
2. Install the three inserts, 4, into the hub, 1. Align
the marks, 5, on the hub, 1, and sleeve, 2, and
start the sleeve on the hub, 1.
3. Push the sleeve, 2, into position and install the
second retaining ring, 3, making sure that both 4
rings are seated inside the lip of the inserts, 4.
4
4. Install the synchronizer rings in the hub, 1, and
assemble the gears to the synchronizers. 2
87
21-40
MAIN COUNTERSHAFT
1
Assembly
3
1. Position the synchronizer and shuttle gear
assembly, 2, minus the front collar, into the
2. Position the fixed countershaft gears, 3, into the
3. Install the main countershaft, 1, into the
transmission housing from the rear, through the
fixed countershaft gears, 3, and the synchronizer
and shuttle gear assembly, 2.
88
4. Install the collar, 1, through the front bearing
counterbore and into the synchronizer and
shuttle gear assembly.
1
10996551
89
5. Install spacer, 2, thickness 0.5mm (0.020″)
between collar, 1, and front bearing, 3.
3 60046478
90
21-41
6. Install the front countershaft bearing, 1, into the
counterbore in the front of the transmission
housing.
1
10996550
91
7. Install the locknut, 1, onto the main countershaft.
Tighten the locknut, 1, and bend the lock tab, 2,
down. 1 2
10996548
92
SHUTTLE SHIFT RAIL AND FORK
Assembly
1
1. Lightly lubricate a new seal, 1, with petroleum
jelly, and install in the transmission housing.
10996547
93
21-42
2. Position the shift fork, 2, on the synchronizer and
install the shift rail, 1, through the transmission
housing.
2 3
3. Install the spacer, 3, onto the shift rail, 1. 1
4. Install the shift rail, 1, through the shift fork, 2, and
into the hole in the transmission housing.
10996546
94
5. Align the roll pin holes in the shift rail, 1, and the
shift fork, 2, and drive a new double roll pin into
the aligned holes.
2 1
10996545
95
6. Install the balk pin, 3, a new seal washer, 2, and
the neutral safety switch, 1, into the side of the
transmission housing. Tighten the neutral safety 1
switch.
2
10996544
96
21-43
7. Install the detent ball, 3, the detent spring, 2, and
detent pin, 1, into the shuttle shift detent hole in
the top of the transmission case.
1
3
10996434
97
REVERSE IDLER SHAFT
Assembly 2
1
1. Use petroleum jelly and lightly lubricate and
install a new O ring, 2, on the end of the idler
shaft, 1.
2. Install the reverse idler shaft, 1, through the
10996543
98
3. Install the two needle bearings, 2, and reverse
idler gear, 1, onto the idler shaft. 2 2
NOTE: Be certain that the oil channels in the reverse
idler gear, face the front of the transmission housing.
10996542
99
21-44
4. Install the thrust washer, 2, onto the idler shaft, 1,
with the oil channels in the spacer facing the
reverse idler gear.
2
5. Using an alignment punch in the roll pin hole,
1
align the locking bolt hole in the idler shaft with
the locking bolt hole in the transmission housing.
10996541
100
6. Install the reverse idler shaft locking bolt, 1, with
a new seal washer and tighten the locking bolt.
10996540
101
7. Install a new roll pin, 1, in the reverse idler shaft,
2.
2
1
10996539
102
21-45
Op. 21 148 63
INPUT SHAFT
1 2
Assembly 4 3
1. Use petroleum jelly and lightly lubricate and
install a new seal, 1, in the end of the input shaft,
4.
2. Install the bearing, 2, in the end of the input shaft,
4, and secure with a new retaining ring, 3.
10996553
103
3. Insert the input shaft, 1, with the reverse gear, 2,
and front bearing, 4, into the front of the 3 2
transmission housing, and through the forward 4
gear, 3. 1
10996538
104
4. Install the rear input shaft bearing, 1, into the
counterbore in the transmission housing.
5. Insert the input shaft through the rear bearing, 1, 1
while positioning the front bearing in the
NOTE: It may be necessary to lightly tap the rear
input shaft bearing to seat it securely on the input
shaft.
10996554
105
21-46
Op. 21 148 63
MAIN COUNTERSHAFT END FLOAT
Assembly
Before installing the retainer housing, the main 1
countershaft end float must be measured and
adjusted. To determine the amount of end float,
perform the following steps: 3
1. Push the main countershaft, 1, towards the rear
of the transmission housing
4
2. Make certain that the face of the transmission
housing is clean and free from any nicks or
sealant material.
3. Place a straightedge, 2, across the housing face
and the main countershaft, 1.
2
4. Insert a feeler gauge, 3, between the front
bearing, 4, and the straightedge, 2, to determine
the amount of end float. 106
5. Use shims, 5, between the retainer housing and
the front bearing to achieve zero end float (end
play).
6. Front bearing, 4, or shims, 5, if required, should
be flush to the front of the transmission case.
NOTE: Shims are available in the following
thickness: 0.1 mm (0.004″), 0.2 mm (0.008″), 0.5 mm
(0.020″).
50046472
107
21-47
Op. 21 148 63
2
RANGE GEAR COUNTERSHAFT
Assembly
1. Install the needle bearing, 1, into the end of the
main countershaft, 2.
10996535
108
2. Position the sliding gears, 3, and large counter
gear, 2, in the transmission housing.
2
3. Slide the range gear countershaft and bearing, 1,

through the rear of the transmission housing, and 1
through the large counter gear, 2.
3
10996533
109
4. Place a new retaining ring, 1, on the range gear
countershaft, 3, temporarily. Do not install the 2
retaining ring in the groove at this point.
1
5. Install the range gear countershaft, 3, through
the sliding gears and into the end of the main
countershaft.
6. Install the retaining ring, 1, in the groove on the
range countershaft, 3, to secure the large
counter gear, 2.
3
10996532
110
21-48
Op. 21 148 63
8
RANGE SHIFT RAIL AND FORK 7
9
Assembly
1. Use petroleum jelly, lubricate and install a new 2
seal, 1, in the transmission housing. 1
2. Install the shift arm, 2, through the transmission
housing, and into the collar on the shift lever, 3. 4
3. Install a new roll pin, 4, through the collar, 3, and
the shift arm, 2.
3
4. Install the locking plate, 5, and the retaining bolt,
6. Tighten the retaining bolt, 6. 5
5. Install the detent spring, 7, and ball, 8, in the shift 6
fork, 9.
10996569
111
6. Position the shift fork, 2, on the sliding gears, 3.
Install the shift rail, 1, through the rear of the
transmission housing. Rotate the shift rail, 1, into
a position that places the detent slots facing up. 2
1
10996530
112
7. Insert the detent tool NH #FNH00081, CIH
#CAS2788, 1, into the detent hole in the shift fork, 1
2. Push down on the detent ball, and hold until the
shift rail, 3, is inserted into the shift fork, 2, far
enough to secure the detent ball. Remove the
2
detent tool, 1.
3
8. Insert the shift rail, 3, through the shift fork, 2, and
into the hole in the transmission housing. Rotate
the shift rail so the detent slots engage the detent
ball, and the locking hole in the shift rail aligns
with the locking bolt hole in the transmission
case.
10996555
113
21-49
9. Install the locking bolt with a new seal washer,
and tighten.
10996528
114
Op. 21 148 63
MAIN SHAFT 2
1
Assembly
1. Install the bearing holder, 2, and the bearing, 1,
into the bore in the transmission housing.
2. Assemble the synchronizers as described earlier
in this section. Install the main transmission
gears on the synchronizers.
10996536
115
3. Install the main shaft, 2, through the rear of the
transmission housing, 3, and position the small, 1
fixed range gear, 1, on the main shaft, 2. 2
10996451
116
21-50
4. Install the adjusting collar, 1, onto the main shaft,
2. 1
10996450
117
5. Install the large, fixed range gear, 1, onto the
main shaft, 2. 1
2
10996449
118
6. Install the main shaft center bearing, 2, onto the
main shaft, 1. 2
10996448
119
21-51
NOTE: When installing the main shaft, make sure
that the main shaft center bearing remains out of its
bore until the gear teeth on the rear of the main shaft 1
are in position.
7. Feed the main shaft, 2, through the center bore

in the transmission housing, and install the rear
synchronizer and gear assembly, 1, on the main
shaft, 2.
10996447
120
NOTE: The range gears and the main gears must be
worked onto the main shaft splines while installing
the main shaft to prevent binding and possible
damage to the gear teeth. 1
2
8. Install the front synchronizer and gear assembly,
1, on the main shaft. Insert the main shaft into the
end of the input shaft while positioning the center
bearing, 2, in its bore.
10996446
121
9. With the main shaft in place, install the rear main
shaft bearing, 1.
1
10996570
122
21-52
MAIN SHAFT END FLOAT

Assembly
Before installing the retainer housing, the main shaft 4
end float must be measured and adjusted. To
determine the amount of end float, perform the
following steps: 1
1. Push the main shaft, 1, towards the rear of the
transmission housing
2
2. Make certain that the face of the transmission
housing is clean and free from any nicks or 3
sealant material.
3. Place a straightedge, 2, across the housing face
and the main countershaft, 1.
4. Insert a feeler gauge, 3, between the front 50046473
bearing, 4, and the straightedge, 2, to determine 123
the recess depth of bearing from the housing
face.
5. Measure the depth of the retainer housing
protrusion, 5. 6
6. To determine the correct shim thickness:
Recess depth of bearing
minus (--) Retainer housing protrusion
Equals = Correct shim thickness to
obtain zero end play
7. Use shims, 6, between the retainer housing and
the front bearing to achieve zero end float (end
play).
5
NOTE: Shims are available in the following
thickness: 0.2 mm (0.008″), 0.5 mm (0.020″).
50046472
124
21-53
Op. 21 148 63
MAIN SHAFT GEARS END FLOAT
Assembly
If new main shaft components were installed when
reassembling the transmission, the gears end float
will need to be measured and adjusted to attain zero 2
end float (play), on the main shaft. To do this, the 1
transmission must be mounted to the rear axle
housing. Zero end float is accomplished by using the
adjusting collar, 1, and collar nut, 2. Use a new collar
assembly. Begin with the collar adjusted all the way
in. Adjust the collar out until zero end play is
achieved. When the adjustment is correct, stake the
lock tab on the collar nut, 2, to secure the adjustment
from changing.
When adjustment is correct, gears should rotate by

hand with a very slight drag. 10996568
NOTE: Do not over expand the adjustment collar. If 125

end float is set too tight, hard shifting and gear drag
will occur.
21-54
MAIN SHIFT RAILS AND FORKS

Assembly
1. Using petroleum jelly, lightly lubricate and install
new shift rail seals, 1, in the transmission
1
housing.
10996552
126
2. Install the detent spring, 1, and the detent ball, 2,
in the detent hole for the main shift rails. 2
10996571
127
3. Position the lower shift fork, 1, on the front
synchronizer, 2. 2
10996558
128
21-55
4. Install the lower shift rail, 1, through the front of
the transmission housing, 2, with the detent
grooves, 3, positioned on the sides of the shift
rail.
2
3
10996442
129
5. Insert detent tool (NH #FNH00081, CIH
#CAS2788), 1, into detent hole, and push down
on the detent ball and spring while sliding the 2
1
lower shift rail, 2, through the transmission
housing, and the shift fork, 3. Remove the detent 2
tool from the hole when the shift rail secures the
detent ball. Turn the shift rail 90° so that the
detent grooves are positioned on the bottom of
the shift rail.
10996444
130
6. Align the roll pin holes in the shift rail, 1, and the
shift fork, 2. Install a new roll pin through the shift
rail, 1, and into the shift fork, 2.
1
2
10996438
131
21-56
7. Position the lower shift rail to place the front
synchronizer, 1, in the neutral position.
1
10996558
132
8. Insert the balk pin, 1, in the detent hole.
1
10996557
133
9. Position the upper shift fork, 1, on the rear
synchronizer, 2.
2
10996559
134
21-57
10. Install the upper shift rail, 1, through the front of
the transmission housing, and through the shift
fork, 2. Align the roll pin holes in the rail and fork. 1 2
Install a new roll pin through the shift fork, 2, and
into the shift rail, 1.
10996439
135
11. Install the PTO shaft, 1 through the main shaft, 2.
10996563
136
RETAINER COVER
Assembly 2
1. Using petroleum jelly, lightly lubricate and install
a new input shaft seal, 1, in the retainer cover, 2. 1
10996561
137
21-58
2. Install a new gasket, 1, between the retainer
cover, 2, and the transmission housing. 2 1 3 4
3. Install the retainer cover, 2, on the transmission
housing. Secure with the six mounting bolts, 3,
and six new seal washers, 4. Tighten the
mounting bolts. See “Bolt Torque Specifications”
in this section for proper bolt torque.
10996565
138
Op. 21 110 10
CLUTCH HOUSING
1
Assembly
1. Install the clutch housing onto the transmission.
Apply Loctitet 242 to the seven buckle-up bolts,
and three buckle-up nuts.
IMPORTANT: Tighten the buckle up hardware to the
following specifications:
2
M12 bolts and nuts 90 N⋅m (66 ft. lbs.)
M14 fine thread bolts, 1, 135 N⋅m (100 ft. lbs.)
10996436
NOTE: Place sealant around the two holes in the 139
casting where the M14 bolts, 1, are installed, to
prevent any oil seepage.
2. Install the diverter valve, 3, and the hydraulic
tubes, 2, onto the transmission housing, using 1
the diverter valve bracket and retaining bolt, 1.
Tighten the retaining bolt, 1. 2
3
10996435
140
21-59
3. Install the detent ball, 3, spring, 2, and pin, 1, into
the shuttle shift detent hole in the transmission
housing.
1
3
10996434
141
4. Install the detent ball, 2, and spring, 1, into the
main gear detent hole, 3, in the transmission
housing. 1
3
10996433
142
5. Apply a bead of Loctitet gasket eliminator 518
to the transmission housing and install the 3 1 2
transmission cover, 2, on the transmission
housing, 3, and secure with the retaining bolts, 1.
Tighten the retaining bolts, 1, and torque to 22.6
- 28.4 N⋅m (16.6 - 21 ft. lbs.).
10996432
143
21-60
6. Install the shuttle gear selector shaft, 1, into the
clutch housing, 2.
NOTE: Be sure to grease the selector shaft before 1
installing the transmission to the engine. Use the
grease fitting, 3.
10996431
144
7. Install and tighten the three retaining bolts, 1,
securing the shuttle gear selector shaft, 2, to the
clutch housing.
2
1
10996430
145
8. Install the main gear selector shaft, 1, into the
clutch housing, 2.
NOTE: Be sure to grease the selector shaft at the
grease fitting, before installing the transmission to
the engine. 1
10996429
146
21-61
9. Install and tighten the three retaining bolts, 1,
securing the main gear selector shaft, 2, to the
clutch housing.
2
1
10996428
147
10. Install the clutch hub and bearing, 1, onto the
input shaft, 2. 2
10996427
148
11. Install the retainer pin, 1, into the clutch housing,
2.
1
10996426
149
21-62
12. Install the clutch hub return spring, 1, onto the
clutch hub, 2, and the retainer pin, 3.
1
2 3
10996562
150
13. Apply a bead of Loctitet gasket eliminator 518
to the rear face of the transmission housing.
14. Use a suitable hoist or lifting device attached to 1
the transmission housing to position the
transmission and the differential together. Apply
Loctitet 242 to the buckle-up bolts and nuts.
Install and tighten the the eight buckle-up bolts,
1, and two buckle-up nuts to 81 N⋅m (60 ft. lbs.).
10996437
151
21-63
1
5
4
20000906
152
ATTACHING THE 12 X 12 TRANSMISSION
TO THE ENGINE
WARNING
1. Install the brake/clutch pedal assembly, 5, onto

2. Attach the left brake rod, 3, to the clutch pedal
linkage, 4.
3. Connect the right brake rod, 1, to the brake
pedals, 2.
21-64
4. Attach the range selector link, 1, to the control
arm, 2, on the transmission.
20000907 1
153
5. Attach the clutch rod to the clutch arm on the
clutch housing.
the engine. Align the splines on the 12 x 12 input 1
shaft with the clutch and the engine flywheel. 2
the clutch/flywheel. The floor jack or the hoist
may need to be raised or lowered to make
alignment possible.
10998241
154
and nuts to 43.4 - 55.6 N⋅m (32 - 41 ft. lbs.). Torque
the two M12 bolts to 81 N⋅m (60 ft. lbs.).
1
3
2
20000905
155
21-65
the tractor.
10000868
156
9. Connect the fuel supply line, 1, to the fuel
shutoff/filter, 3, and connect the fuel tank vent
line, 2, to the tee fitting.
1
2
3
10000865
157
and the clutch housing, 3. Secure with the
retaining bolts.
2
1
20000908
158
21-66
11. If equipped, Install the FWD driveshaft, 2, and
secure with the two roll pins, 1.
1
20000904
159
the starter, 2. 2
30997565
1
160
the hydraulic pump, 2, and the diverter valve. 2
hydraulic pump, 2.
15. Connect the main wiring harness connector.
17. Connect the throttle cable to the foot throttle
control lever located on the right deck.
3
19. Install the seat and the seat base on the tractor.
30997557
161
ROPS.
21-67
valve, 1, on the right fender. Connect the
hydraulic tubes.
23. Connect the wiring connectors to the dash
housing switches.
throttle control lever.
1
30997555
162
instrument panel. Install the instrument panel, 2, 2 1
into the dash housing, 3, and secure with two
screws, 1. 1
10035024
163
bracket, 8, to the steering column, 9, with the
retaining bolts, 6. Connect the lower main shift
shaft, 5, and shuttle shift shaft, 2, to the
transmission shafts with the roll pins, 4 and 1,
and retaining ring, 3.
27. Install the hood on the tractor and connect the
headlight wiring connector. 6 9
8 7 6
2
4 5
1
3
10996566
164
21-68
panels.
29. Fill the hydraulic reservoir with Hy-Tran Ultra
hydraulic fluid, to the proper level.
tractor.
2
1
recommended oil to the proper level.
10000864
165
1 2
30997558
166
21-69
2
1
10996567
167
Op. 21 130
TRANSMISSION SHIFT LEVERS
1. Shuttle Shift Control Lever
2. Main Transmission Shift Control Lever
21-70
4 3
10 5
12
11
14
13 6
15
7
9
1 2
16
8 17
10996566
168
MAIN SHIFT CONTROL LEVER Installation
Removal 1. Install the main shift control lever assembly
through the dash and onto the clutch housing.
1. Remove the rear hood shields to gain access to
the shift levers. 2. Install the two retaining bolts, 6, through the main
shift control bracket, 7, into the steering column,
2. Remove the roll pin, 1, from the U joint, 2. 15. Tighten the retaining bolts, 6.
3. Remove the lever grip, 3, and the shift boot, 4, 3. Install the shift boot, 4, and the lever grip, 3, onto
from the shift lever, 5. the shift lever, 5.
4. Loosen and remove the two retaining bolts, 6, 4. Install a roll pin, 1, through the U joint, 2, and the
from the main shift control bracket, 7. main shift shaft, 16.
5. Remove the main shift control lever assembly 5. Install the rear side hoods.
from the clutch housing and the dash.
6. Use conventional repair procedures to overhaul
the shift control lever assembly.
21-71
10996567
169
MAIN SHIFT LEVER main shift control bracket, 7, to give equal motion
between neutral, and the up and down gear
Adjustment positions.
1. Loosen the two retaining bolts, 6, and slide the
gearshift assembly up or down in the slots on the
21-72
4 3
10 5
12
11
14
13 6
15
7
9
1 2
16
8 17
10996566
170
SHUTTLE SHIFT CONTROL LEVER Installation
Removal 1. Install the shuttle shift control lever assembly
through the dash and onto the clutch housing.
1. Remove the rear hood shields to gain access to
the shift levers. 2. Install the two retaining bolts, 13, through the
shuttle shift control bracket, 14, into the steering
2. Remove the roll pin, 8, from the shuttle control column, 15. Tighten the retaining bolts, 13.
shaft, 9.
3. Install the shift boot, 11, and the lever grip, 10,
3. Remove the lever grip, 10, and the shift boot, 11, onto the shift lever, 12.
from the shift lever, 12.
4. Install a roll pin, 8, through the shuttle control
4. Loosen and remove the two retaining bolts, 13, shaft, 9, and the shuttle shift shaft, 17.
from the shuttle shift control bracket, 14.
5. Install the rear side hoods.
5. Remove the shuttle shift control lever assembly
from the clutch housing and the dash.
6. Use conventional repair procedures to overhaul
the shift control lever assembly.
21-73
21-74
SECTION 23 - DRIVELINE - CHAPTER 1
SECTION 23 - DRIVELINE
Chapter 1 - Driveline
CONTENTS

23 000 Bolt Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
23-1
BOLT TORQUE SPECIFICATIONS

4T, 4.8 3.6 -- 5.1 4.9 -- 6.9
M6 7T, 8T, 8.8 1.0 6.1 -- 8.3 8.3 -- 11.3 ------------ ------------ ------------
10T, 11T 8.6 -- 11.6 11.7 -- 15.7
4T, 4.8 9.4 -- 12.3 12.7 -- 16.7 11.2 -- 14.9 15.2 -- 20.2
M8 7T, 8T, 8.8 1.25 16.7 -- 21.0 22.6 -- 28.4 1.0 19.6 -- 25.3 26.5 -- 34.3
10T, 11T 21.0 -- 26.8 28.5 -- 36.3 22.4 -- 29.7 30.4 -- 40.2
4T, 4.8 18.8 -- 24.6 25.5 -- 33.3 21.0 -- 26.8 28.5 -- 36.3
M10 7T, 8T, 8.8 1.5 32.5 -- 41.3 44.1 -- 55.9 1.25 36.2 -- 46.3 49.0 -- 62.8
10T, 11T 39.8 -- 51.3 54.0 -- 69.6 42.7 -- 54.2 57.9 -- 73.5
4T, 4.8 27.5 -- 34.8 37.3 -- 47.1 31.8 -- 40.5 43.1 -- 54.9
M12 7T, 8T, 8.8 1.75 48.5 -- 61.5 65.7 -- 83.3 1.25 54.9 -- 69.4 74.5 -- 94.1
10T, 11T 68 -- 85.6 92 -- 116 73.1 -- 93.7 99 -- 127
4T, 4.8 46.3 -- 59.3 62.8 -- 80.4 51.4 -- 64.4 69.7 -- 87.3
M14 7T, 8T, 8.8 2.0 76.8 -- 97.4 104 -- 132 1.5 85.6 -- 109 116 -- 148
10T, 11T 102.6 -- 129 139 -- 175 110 -- 136 149 -- 185
4T, 4.8 63.5 -- 81.2 86 -- 110 67.2 -- 84.9 91 -- 115
M16 7T, 8T, 8.8 2.0 110 -- 136.5 149 -- 185 1.5 116 -- 142 157 -- 193
10T, 11T 151.3 -- 188 205 -- 255 162 -- 199 220 -- 270
4T, 4.8 83.4 -- 104 113 -- 141 96.7 -- 120 131 -- 163
M18 7T, 8T, 8.8 2.0 145 -- 174 196 -- 236 1.5 169 -- 206 230 -- 280
10T, 11T 203 -- 246 275 -- 333 220 -- 270 299 -- 367
4T, 4.8 106 -- 133 144 -- 180 126 -- 155 171 -- 211
M20 7T, 8T, 8.8 2.5 177 -- 214 240 -- 290 1.5 203 -- 245 275 -- 333
10T, 11T 268 -- 252 363 -- 341 293 -- 358 397 -- 485
23-2
SPECIAL TOOLS
Detent ball retaining tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #FNH0081, CIH #CAS2788
23-3
FRONT WHEEL DRIVE TAKE OFF an output shaft, 6, and a shift fork. These
GEARBOX components when engaged by the operator’s control
lever, transfer drive power to the front axle, making
The front wheel drive take off gearbox, is mounted
both the rear and the front wheels of the tractor
underneath the rear differential housing and consists
driven.
of a fixed gear, 1, on the final drive pinion shaft, 2, a
fixed gear, 3, and a sliding gear, 4, in the gearbox, 5,
6 3 4
20000950 2 5
2
23-4
TROUBLESHOOTING
CONDITION POSSIBLE CAUSE REMEDY

Driveline vibration 1. Dry U-joints or driveshaft cou- 1. Lubricate
plings
2. Worn U-joints or couplings 2. Replace U-joints/couplings
3. Bent driveshaft 3. Replace driveshaft
FWD will not stay engaged 1. Control lever out of adjustment 1. Adjust lever linkage
2. Excessive FWD wrap up 2. Check front to rear tire ratio
LUBRICATION
The driveline must be lubricated every 50 hours, or Use High Viscosity Lithium Base-NLGI#2 grease,
sooner if necessary. The universal joints have grease and Hy-Tran Ultra hydraulic oil for lubrication of the
fittings while the Front Wheel Drive Take Off Gearbox driveline.
is lubricated by the hydraulic oil in the differential
case.
23-5
OVERHAUL
FRONT WHEEL DRIVE TAKE OFF

2 2
GEARBOX 6
Removal
1. Loosen and remove the retaining bolts, 1, and 3
the covers, 2, from the drive shaft, 3.
2. Drive out the roll pin, 4, from the coupler, 5. Drive 4
out the roll pin, 6, from the coupler, 7.
3. Remove the couplers, 5 and 7, and the drive 7 1
shaft, 3, from the tractor.
5
20000944
4. Loosen and remove the drain bolt, 1, and the

sealing washer, 2, from the gearbox, 3, and drain
the hydraulic fluid into a suitable container.
5. Loosen and remove the seven mounting bolts, 4,
2
from the gearbox, 3. Remove the gearbox from 3
the differential housing. 1
4
20043766
23-6
13
14
12
9
6
8
20 7
18 3
19
17
16 5 22
25 21
17 1 24
2 4
23
15
10 11
20000946
1 Drain Plug 14 Spring

2 Sealing Washer 15 Bolt M8 x 25 mm
3 Gearbox Housing 16 Driveshaft Retainer
4 Bolt M8 x 45 mm 17 O ring
5 Roll Pin 18 Seal
6 Countershaft 19 Bearing
7 Thrust Washer 20 FWD Output Shaft
8 Needle Bearing 21 Sliding Gear
9 Counter Gear 22 Bearing
10 Bolt M8 x 16 mm 23 O ring
11 Shift Rail 24 Bolt M8 x 35 mm
12 Shift Fork 25 Bolt M8 x 25 mm (5)
13 Detent Ball
23-7
Disassembly Assembly
1. Drive out the roll pin, 5, from the counter gear 1. Install the rear bearing, 22, into the gearbox
shaft, 6. housing, 3.
NOTE: Observe the orientation of the counter gear 2. Install the output shaft, 20, into the gearbox, 3,
flanges before removing the gear. The long flange is and through the sliding gear, 21.
positioned toward the front of the gearbox, and the
3. Install the front bearing, 19, into the gearbox, 3.
short flange faces rearward. Observe the orientation
of the oil grooves on the thrust washers. The oil 4. Lightly lubricate a new oil seal, 18, with
grooves face the counter gear. petroleum jelly, and install into the gearbox, 3.
5. Lightly lubricate new O rings, 17, with petroleum
2. Remove the counter gear shaft, 6, the two thrust jelly, and install onto the drive shaft retainer, 16
washers, 7, the two needle bearings, 8, and the
counter gear, 9, from the gearbox, 3. 6. Secure the drive shaft retainer, 16, to the
gearbox, 3, with the retaining bolt, 15.
3. Loosen and remove the shift rail retaining bolt,
10, from the gearbox, 3. 7. Install the shift fork, 12, onto the sliding gear, 21.
WARNING 8. Install the detent spring, 14, and the detent ball,
13, into the detent hole in the shift fork, 12.
Place a rag over the detent hole in the shift fork
when removing the shift rail. The detent ball and 9. Lightly lubricate and install a new O ring, 23, onto
spring could be expelled with considerable force the shift rail, 11.
resulting in personal injury. 10. Insert the special detent tool, (NH #FNH0081,
CIH #CAS2788), into the shift fork detent hole,
4. Turn the shift rail, 11, 90° and remove from the and push down while installing the shift rail, 11,
gearbox, 3. into the shift fork, 12.
5. Remove and discard the O ring, 23, from the shift 11. Install and tighten the shift rail retaining bolt, 10,
rail, 11. into the gearbox case, 3.
6. Remove the shift fork, 12, from the gearbox, 3. NOTE: Observe the orientation of the counter gear
Do not lose the detent ball, 13, and spring, 14. flanges while installing the gear. The long flange is
7. Loosen and remove the bolt, 15, securing the positioned toward the front of the gearbox, and the
drive shaft retainer, 16, to the gearbox, 3. short flange faces rearward. Observe the orientation
of the oil grooves on the thrust washers. The oil
8. Remove the drive shaft retainer, 16, from the grooves face the counter gear.
gearbox, 3. Remove and discard the O rings, 17.
9. Remove and discard the oil seal, 18. 12. Install the counter gear shaft, 6, the two thrust
washers, 7, the two needle bearings, 8, and the
10. Remove the front bearing, 19, from the counter gear, 9, into the gearbox, 3.
gearbox, 3.
13. Install a new roll pin, 5, in the counter gear
11. Gently tap the output shaft, 20, out of the shaft, 5.
gearbox, 3.
12. Remove the sliding gear, 21, from the Installation
gearbox, 3.
1. Install the gearbox, 3, to the differential housing,
13. Remove the rear bearing, 22, from the and secure with the seven retaining bolts, 4.
gearbox, 3.
2. Install the drain bolt, 1, with a new sealing
Inspection washer, 2, into the gearbox, 3, and tighten.
1. Clean all parts in a suitable solvent and air dry. 3. Fill the common hydraulic fluid reservoir to the
2. Inspect the gears for excess wear or damage. proper level with AMBRA MULTI G134 hydraulic
fluid.
3. Rotate the bearings by hand and check for
roughness. Replace as necessary.
4. Inspect all parts for excess wear or damage.
Replace as necessary.
23-8
4. Install the couplers, 5 and 7, to the drive shaft, 3.
Install the drive shaft to the tractor. 2 2
6
5. Install the roll pins, 4 and 6, in the couplers, 5
and 7. 3
6. Install the covers, 2, to the drive shaft, 3, and
secure with the retaining bolts, 1. Tighten the
4
retaining bolts, 1.
7 1
5
20000944
6
23-9
23-10
SECTION 25 -- FWD FRONT AXLE -- CHAPTER 1
Chapter 1 - FWD Front Axle
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front to Rear Axle Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FWD Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Lubricate Every 50 Hours -- Standard FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Standard FWD Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
25 108 Gear Reduction Drop Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
25 102 Front Axle and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Gear Reduction -- Drop Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Differential Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Axle and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Differential Case Bearing Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
25-1

25 108 Gear Reduction Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Bevel Gear-to-Pinion Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
25-2
SPECIFICATIONS
Power Steering
g Pump
p
Flow @ 2600 rpm, 2WD and FWD 19.4 lpm (5.13 gpm)
Power Steering Type Full Hydraulic
Relief Valve Pressure
FWD 100-105 bar (1450 - 1520 psi)
Reservoir
Capacity
p y 1.4 L (1.5
( US qts.)
q )
Oil Hy-Tran Ultra
Maximum Turning
g Angle
g
FWD 54_
Power Steering
g Hose Fittings
g
Straight
g Fitting g 386.5 - 440.7 N⋅m (285
( - 325 in. lb.))
Swivel Fitting 298.3 - 359.3 N⋅m (220-265 in. lb.)
FRONT TO REAR AXLE RATIO

D35, DX35, D40, DX40, D45 and DX45
IMPORTANT: On tractors equipped with FWD (Front • Engine will lug down or stall when operating on
Wheel Drive) the front to rear axle ratio (1.6605:1, hard surfaces.
with an acceptable range of 1.63 - 1.69:1), is • The front wheel drive lever will not remain in the
critical and must be maintained for safe and efficient engaged position, or is difficult to disengage.
use of the tractor. This ratio applies to all available tire
• Failure of the driveline gears.
options. Following is a list of problems that may occur
if the front to rear axle ratio is not maintained: • Failure of the front axle, ring and pinion gears.
• Premature tire wear.
25-3
To calculate the front to rear axle ratio, use method 3. To change the front to rear ratio, increase or de-
1 or method 2. crease the tire inflation pressure.
Method 1: NOTE: Do not exceed the tire inflation pressures rec-

ommended in the Operator’s Manual. Consult the
1. Obtain a measurement from the center of the Operator’s Manual for the available tire sizes for a
front axle to the ground (Distance A), and center specific tractor.
of the rear axle to the ground (Distance B).
2. Divide Distance B by Distance A to calculate the
front to rear axle ratio. (“B” ÷ “A” = Front to rear
ratio.)
B
A
20000955
25-4
Method 2: Rolling Test 6. Divide the distance B by the distance A to calcu-
late the front to rear ratio.
1. Make a mark on the front tire, 1, and the rear
tire, 2. 7. To change the front to rear ratio, increase or de-
crease the tire inflation pressure, or check the
2. Make a corresponding mark, 3, on the ground at
rear counterbalance weights.
each tire.
NOTE: Do not exceed the tire inflation pressures rec-
3. Slowly roll the tractor forward until the marks on
ommended in the Operator’s Manual. Consult the
the tires, 1 and 2, make one full revolution.
Operator’s Manual for the available tire sizes and
4. Make a second mark, 4, on the ground as in inflation pressures for a specific tractor.
step 2.
5. Measure the distance between the marks on the
ground for each tire.
1 2
A B
4 3 4 3 20000955
25-5

4T, 4.8 3.6 -- 5.1 4.9 -- 6.9
M6 7T, 8T, 8.8 1.0 6.1 -- 8.3 8.3 -- 11.3 ------------ ------------ ------------
10T, 11T 8.6 -- 11.6 11.7 -- 15.7
4T, 4.8 9.4 -- 12.3 12.7 -- 16.7 11.2 -- 14.9 15.2 -- 20.2
M8 7T, 8T, 8.8 1.25 16.7 -- 21.0 22.6 -- 28.4 1.0 19.6 -- 25.3 26.5 -- 34.3
10T, 11T 21.0 -- 26.8 28.5 -- 36.3 22.4 -- 29.7 30.4 -- 40.2
4T, 4.8 18.8 -- 24.6 25.5 -- 33.3 21.0 -- 26.8 28.5 -- 36.3
M10 7T, 8T, 8.8 1.5 32.5 -- 41.3 44.1 -- 55.9 1.25 36.2 -- 46.3 49.0 -- 62.8
10T, 11T 39.8 -- 51.3 54.0 -- 69.6 42.7 -- 54.2 57.9 -- 73.5
4T, 4.8 27.5 -- 34.8 37.3 -- 47.1 31.8 -- 40.5 43.1 -- 54.9
M12 7T, 8T, 8.8 1.75 48.5 -- 61.5 65.7 -- 83.3 1.25 54.9 -- 69.4 74.5 -- 94.1
10T, 11T 68 -- 85.6 92 -- 116 73.1 -- 93.7 99 -- 127
4T, 4.8 46.3 -- 59.3 62.8 -- 80.4 51.4 -- 64.4 69.7 -- 87.3
M14 7T, 8T, 8.8 2.0 76.8 -- 97.4 104 -- 132 1.5 85.6 -- 109 116 -- 148
10T, 11T 102.6 -- 129 139 -- 175 110 -- 136 149 -- 185
4T, 4.8 63.5 -- 81.2 86 -- 110 67.2 -- 84.9 91 -- 115
M16 7T, 8T, 8.8 2.0 110 -- 136.5 149 -- 185 1.5 116 -- 142 157 -- 193
10T, 11T 151.3 -- 188 205 -- 255 162 -- 199 220 -- 270
4T, 4.8 83.4 -- 104 113 -- 141 96.7 -- 120 131 -- 163
M18 7T, 8T, 8.8 2.0 145 -- 174 196 -- 236 1.5 169 -- 206 230 -- 280
10T, 11T 203 -- 246 275 -- 333 220 -- 270 299 -- 367
4T, 4.8 106 -- 133 144 -- 180 126 -- 155 171 -- 211
M20 7T, 8T, 8.8 2.5 177 -- 214 240 -- 290 1.5 203 -- 245 275 -- 333
10T, 11T 268 -- 252 363 -- 341 293 -- 358 397 -- 485
SPECIAL TOOLS
Tool No.
Detent Tool FNH00081, CIH #CAS2788
Seal Driver Set NH00293, CIH #CAS2785
Includes: Handle
Drive Plate -- 2-15/16 in.
in
D i Pl
Drive Plate
t -- 2 iin.
25-6
Op. 25 100
FWD FRONT AXLE
The four-wheel drive front axle is a factory installed
option on the D35, DX35, D40, DX40, D45 and DX45
tractors.
The four-wheel drive system uses the same support-

ing system as the two-wheel drive models. The front
wheel tie rod assembly is adjustable for toe-in
adjustments.
Power to the front axle flows from the final drive pin-
ion gear, in the rear differential, through a take off box
attached to the underside of the rear axle center
housing. The take off box transmits power to the front
axle drive pinion through a drive shaft.
Power to the front wheels flows from the front axle dif-
ferential side gear, 1, and axle shaft, 2, to the front
wheel reduction drop box, 4, assembly.
A pinion gear, 3, on the axle shaft, 2, drives an idler

pinion, 5, and an idler shaft, 6, in the drop box. A final
drive pinion, 7, on the idler shaft, 6, drives a bevel
gear, 8, which is splined to the wheel hub and shaft
assembly, 9.
The front wheel drive is controlled by a control lever

located on the left control pod on DX35, DX40 and
DX45 model tractors and by a control lever located
to the left of the operator’s seat on the D35, D40 and S-23099
D45 model tractors. 3
25-7
TROUBLESHOOTING
Most malfunctions in the steering system can usually 2. Jack the front end of the tractor off the ground
be traced to dirt or foreign matter in the system. Dirt and cycle the steering from stop to stop to check
can cause such things as stickiness, erratic opera- for front axle binding.
tion, or hard steering.
3. Be sure the hydraulic hoses from the pump-to-
Before considering the procedures below, follow motor and from the motor-to-cylinder are hooked
these suggested steps: up correctly.
1. Check the pump for proper relief valve action.

See “Pressure Testing,” discussed later in this
section.

Hard Steering 1. Control valve unit
Control valve unit not aligned to Reposition control valve unit. (If loos-
steering column ening its mounting bolts lightens the
handwheel, it means that control
valve unit was in misalignment)
Spool-and-sleeve combination is Replace

seized because of foreign matter.
Over tightening of the end cap bolts Re-tighten to the specified torque
limit
2. Oil pump
The pump is stuck and will not work Replace oil pump
The pump is worn down Replace oil pump
Pumping performance inadequate Test pump performance and, if nec-

essary, remove the pump. Disas-
semble the pump and inspect the in-
ternal seals. Refer to the pump seal
kit repair section
3. Relief valve
The valve is damaged because of Replace control valve assembly

internal deterioration.
Pressure setting is too low Replace control valve assembly

Steering wheel will not return 1. Control valve unit
to neutral or will turn by itself
Spool and sleeve combination is Replace control valve
stuck and will not rotate assembly
Control valve unit not aligned to Re-align

steering column
25-8

Cylinder will not follow steering 1. Control valve unit
wheel rotation or will respond
sluggishly Control valve unit has been improp- Repair
erly rebuilt, resulting in valve mistim-
ing
2. Steering cylinder
Air is trapped in the cylinder Bleed air out
Internal oil leakage because of dam-

aged piston seal Replace the seal
Steering wheel will “kick back” 1. Control valve unit
Control valve unit has been improp- Repair

erly rebuilt, resulting in valve mistim-
ing
2. Piping
Pipes are improperly connected to Correct the pipe connections

the four ports of Control valve unit
Oil leakage
1. From the splined connec- 1. Leaky oil seal Replace the seal
tion of column to spool
Dirty hydraulic oil Change the oil
2. From mated face joints 2. Damaged O ring Replace

(valve body, spacer plate,
Control valve unit, end cap)
Front wheel Shimmy 1. Worn pivot shaft and/or bushings Replace pivot shaft and/or bushings
2. Loose tie-rod Tighten tie-rod
3. Loose spindle arm Tighten spindle arm
4. Worn king pin and/or bearing Replace king pin and/or bushing
Loose Spindle 1. Worn bushing Replace bushing
2. Worn spindle shaft Replace spindle shaft
3. Worn or damaged thrust bearing Replace thrust bearing

Hard steering 1. Faulty power steering system Inspect and repair power steering
system
25-9
LUBRICATION
Lubricate Every 50 Hours - Standard FWD

1. Tie rod - right side 1 2
2. Tie rod - left side
3. Steering cylinder - barrel end
4. Steering cylinder - rod end 4
5. Front bearing holder
6. Rear bearing holder
6
3
5
4
25-10
OVERHAUL
STANDARD FWD AXLE

2 2
Removal 6
1. Drain the power steering reservoir and remove
the power steering hoses from the steering 3
cylinder.
2. Loosen and remove the retaining bolts, 1, and 4
the covers, 2, from the drive shaft, 3.
3. Drive out the roll pin, 4, from the coupler, 5. Drive 7 1
out the roll pin, 6, from the coupler, 7.
4. Remove the couplers, 5 and 7, and the drive- 5
shaft, 3, from the tractor. 20000944
5. Raise the tractor with a floor jack and support the 5

frame with jack stands.
6. Remove the front pivot bearing holder, 1, and the

rear pivot bearing holder, 2, from the tractor 2
frame.
7. Carefully roll the front axle assembly forward, out
from under the tractor.
200000945
6
Installation
1. With the tractor supported on jack stands, care-
2
fully roll the front axle under the tractor.
2. Install the rear pivot bearing holder, 2, and the
front pivot bearing holder, 1, onto the axle and the
frame of the tractor.
1
3. Raise the tractor using a floor jack, and remove
the jack stands. Lower the tractor and remove the
floor jack.
200000945
7
25-11
4. Install the coupler, 7, onto the drive shaft, 3, using
the roll pin, 6. 2 2
6
5. Install the coupler, 5, onto the drive shaft, 3. Do
not install the roll pin, 4, at this time. 3
6. Install the drive shaft assembly onto the tractor.
7. Install the roll pin, 4, into the coupler, 5 at this 4
time.
8. Install the covers, 2, onto the drive shaft, 3, and 7 1
secure with the retaining bolts, 1.
5
20000944
8
Op. 25 108
GEAR REDUCTION DROP BOX
Disassembly
NOTE: These procedures apply to both the right and
left front axle component assemblies. Repeat the
procedure for the opposite side component to be dis-
assembled or repaired.
1. Remove the front-wheel hub bolts and remove
the front wheels. 4
2. Remove the tie rod, 1, from the steering arm, 2.
Tap the ball joint with a hammer to loosen the ball
joint.
3. Remove the drain plug, 3, from the drop box 1
case, and drain the oil into a clean suitable con-
tainer.
4. Remove the steering cylinder, 4, from the steer-
ing arm, and the front axle.
S-23765
25-12
23 24
35 36 21 22
3 20
1 2 18
19
16 17
14
4 15 13 37
12
11
7
42 31
38
32
29
6 30
5
9 34 33
8 10
39 25
40 26
27 28
41
43
30996399
10
1. Wheel Hub and Shaft 23. Adjuster Screw
2. Oil Seal 24. Nut Cap
3. Bolt 25. Idler Shaft
4. Case Cover 26. Final Drive Pinion Gear
5. Ball Bearing 27. Ball Bearing
6. Clip 28. Cover
7. Final Drive Bevel Gear 29. Nut
8. Ball Bearing 30. Bolt
9. L.H. Drop Box Casing Assembly 31. Plug
10. R.H. Drop Box Casing Assembly 32. Seal Washer
11. Tapered Roller Bearing 33. Drain Bolt
12. Oil Seal 34. Seal Washer
13. Idler Casing Assembly 35. Left Side Bolt
14. Idler Pinion Gear 36. Right Side Bolt
15. Ball Bearing 37. Ball Bearing
16. Snap Ring 38. Dowel Pin
17. Kingpin 39. Stud Bolt
18. O ring 40. Spring Washer
19. Ball Bearing 41. Nut
20. Spacer 42. Dowel Pin
21. L.H. Steering Arm 43. Bolt
22. R.H. Steering Arm
25-13
5. Remove the case cover bolts, 3, and remove the 9. Remove the idler case, 13, from the front axle.
wheel hub, 1, cover, 4, and final bevel gear, 7, as
10. Remove the oil seal, 12, and the tapered roller
an assembly.
bearing, 11, from the drop box, 9 or 10.
WARNING 11. Remove the wheel hub shaft inner bearing, 8,
The drop box, 9 or 10, is free to disengage and fall from the wheel hub shaft, 1, and remove the final
away from the idler gear case, 13, when the drive bevel gear, 7.
steering arm, 21 or 22, bolts, 35 and 36, are 12. Remove the split ring, 6, and gently drive the
removed. Use care to avoid accidental disen- wheel hub shaft assembly, 1, from the cover, 4.
gagement of the components. Uncontrolled
dropping of the components may cause personal 13. Remove the bearing, 5, and the oil seal, 2, from
injury. the cover, 4.
14. Remove the idler pinion gear, 14, and the bear-
6. Remove the four retaining bolts, 35 and 36, from ings, 15 and 37, from inside the idler case, 13.
the steering arms, 21 or 22. 15. Remove the axle drive pinion gear and O ring
7. Remove the drop box case, 9 or 10, the final drive seal from the front axle housing.
pinion gear, 26, and the idler shaft, 25,as an as- 16. Remove the spacer, 20, the bearing, 19, the king-
sembly from the idler case, 13. pin, 17, the O ring, 18, and the snap rings, 16,
8. Remove the four bolts, 43, from the final drive from the idler case, 13.
pinion cover, 28. Remove the final drive pinion
gear, 26, the bearing, 27, the cover, 28, and the
shaft, 25, as an assembly from the drop box, 9
or 10.
25-14
Op. 25 102
9 2
FRONT AXLE AND DIFFERENTIAL
8 4
Disassembly 6
1. Remove the left axle housing retaining bolts, 1, 7
5
and remove the axle housing, 2, and the axle
shaft, 3, as an assembly.
10
2. Remove the differential assembly, 4, and differ-
ential carrier bearings, 5, from the axle housing, 5
2.
6
3. Remove the O ring, 6, the axle outer pinion gear, 3
1
8, and bearing, 7, from each end, and gently drive
the axle shaft, 3 and 9, inward to remove from the 11
housing.
NOTE: Observe the quantity and the size of the
shims, 6, between the axle shaft inner bearing and
the axle housing. Shim sizes are 0.1 mm (0.004″),
0.2 mm (0.008″), and 0.5 mm (0.020″).
4. Check the differential side gear to pinion back-

lash. Replace the gears if backlash exceeds 0.3
mm (0.012″).
25-15
5. Remove the bolts, 1, from the differential case 8. Remove the four pinion gears, 8, and thrust
cover, 2. washers, 9.
6. Remove the differential side gear, 4, and the 9. Remove the support bearings, 10 and the ring
thrust washer, 3. gear, 11, from the case, 7.
7. Remove the pinion gear shaft retaining ring, 5,
and slide the pinion shaft, 6, out of the case, 7.
9
2
8
10 3
4
11
4
6 6
3
5
1
10
9
20000947
12
DRIVE PINION
7 9
Disassembly
2 1 4
1. Remove the drive pinion locknut, 10.
2. Remove the collar, 8, the O ring, 7, the oil seal,
9, and the bearing, 6.
10
3. Gently drive the pinion shaft, 1, inward, and re- 6
move the pinion assembly with the bearing, 5 and 5
the shims, 4, from the case, 2.
8
shims used on the pinion shaft. Shim sizes are 0.1
mm (0.004″), 0.2 mm (0.008″), and 0.5 mm (0.020″). 20000948
13
4. Remove the bearing, 5, and the shims, 4, from
the pinion shaft, 1.
25-16
FRONT AXLE
1
Inspection
1. Wash all parts in a suitable solvent and air dry.
2. Inspect the axle pivot bearing retainer for cracks,
excessive pitting, wear, or distortion. Replace if
found to be defective.
14
DIFFERENTIAL
Inspection
measure the pinion gear bore and the pinion
shaft to determine the bore to shaft clearance.
Replace the gear and/or shaft if the clearance ex-
ceeds 0.1 mm (0.004″).
3. Measure the differential to side gear thrust wash-
er thickness. Replace the thrust washers if the
thickness is less than 1.2 mm (0.047″).
NOTE: If the thrust washers are replaced, recheck
the side gear to pinion gear backlash during
assembly. Refer to backlash check made during
disassembly.
4. Inspect all gear teeth for excess wear or damage.

Replace gears if teeth are damaged or wear is
excessive.
GEAR REDUCTION—DROP BOX

Inspection
2. Inspect the gears for excess wear or damage.
Replace gears that show excessive wear or dam-
age. See “Assembly”, for gear backlash checks.
3. Inspect the splines on the pinion gears, idler
shaft, and axle shaft for excess wear or damage.
4. Check the bearings for wear or roughness. Ro-
tate the bearings by hand and replace as re-
quired.
5. On assembly, check the bevel gear and pinion
backlash. See “Gear Reduction—Drop Box As-
sembly”, discussed later in this section.
25-17
DRIVE PINION
7 9
Assembly
2 1 4
1. Install the shims, 4, and the front pinion bearing,
5, on the drive pinion, 1.
10
mm (0.004″), 0.2 mm (0.008″), and 0.5 mm (0.020″). 6
5
2. Insert the drive pinion, 1, in place in the differen- 8
tial housing, 2.
3. Install the outer bearing, 6, on the pinion shaft, 1, 20000948
in the differential housing, 2.
15
4. Using a suitable driver, install the oil seal, 9, the
O ring, 7, and the collar, 8, on the pinion shaft, 1.
5. Install the pinion locknut, 10, and tighten to obtain
the correct bearing preload as follows:
• Wrap a strong cord, 2, around the pinion
shaft, 1. Using a pull scale, 3, measure the 3
pounds of pull required to rotate the pinion 1
shaft. 2
• Tighten or loosen the locknut as necessary to
obtain a preload of 16.3 - 20 kg (35.9 - 44.1 lbs.)
pull.
16
DIFFERENTIAL GEAR
Assembly
2
1. Install the differential ring gear, 1, to the case, 2, 4
and align the mounting bolt holes.
2. Install new locking plates, 3.
3. Install and tighten bolts, 4, to the specified
torque. See “Bolt Torque Specifications”, dis-
1
3
17
25-18
AXLE AND DIFFERENTIAL 9 2

Assembly
8 4
If any of the following components are not being re- 6
placed, assemble the front axle using the original
7 5
components.
Differential assembly, 10
10
Differential case carrier bearings, 5
Axle housing, 1 and 2 5
Axle shaft, 3 and 4 6 3
1
18
1. Install the shim pack, 6, and carrier bearing, 5, in
the differential axle housing, 2.
mm (0.004″), 0.2 mm (0.008″), and 0.5 mm (0.020″).
2. Install the axle shaft, 4, in the housing from the

outer end through the shim pack, 6.
3. Install the axle shaft outer bearing, 7.
4. Position the differential assembly, 10, in the
housing, inserting the differential outer cover end
inside the bearing, 5, previously positioned in the
axle housing, 2.
5. Assemble the left axle shaft and housing in the
same manner described in steps 1 through 4.
6. Apply liquid gasket to the left axle housing mating
surface and align the right and left axle housings
together.
7. Install the axle retaining bolts and tighten to the
specified torque. See “Bolt Torque Specifica-
tions”, discussed earlier in this section.
NOTE: The differential carrier bearing preload and
ring gear backlash must be checked and adjusted if
the differential case bearings, axle shaft inner bear-
ings, or axle shaft have been replaced.
25-19
DIFFERENTIAL CASE BEARING PRELOAD

3
Check and Adjustment
1. Position the differential carrier bearing, 7, and the
shim pack, 1, in place in the right differential axle 1
housing.
2. Place the differential assembly, 5, in the housing,
being sure the differential case is fully seated in-
side the bearing, 7.
3. Position the left differential case bearing, 8, on A
the differential assembly, 5, being sure it is fully 8
seated.
B
4. Measure the distance “A” and measure the dis-
tance “B”. Add or subtract shims, 1 or 2, from the
shim pack so that the measurements “A” - “B” =
0.15 mm (0.006″). 6
4
7 2
19
RING GEAR-TO-PINION BACKLASH
Ring gear-to-pinion backlash must be checked and
adjusted whenever new components are used or if
the shim requirements are unknown.
NOTE: This is a continuation of the carrier bearing

preload adjustment.
1. Position the assembled axle housing assembly

in a vertical position, supported by the housing
and not the shaft.
NOTE: For personal safety, be sure the assembly is
properly supported to prevent falling.
2. Position the differential assembly in the housing,

being sure the differential case is fully seated in
the bearing and axle housing counterbore.
NOTE: Be sure there is clearance between the ring
gear and the pinion gear. There must not be any in-
terference.
25-20
3. Place a dial indicator, 1, on the axle housing so
that it rests upon a casing bolt, 2. Rock the ring 2
gear, 4, back and forth by turning the pinion shaft,
3, to obtain the ring gear free-play clearance on
1
the dial indicator.
4
3
20
4. If the reading is not within the range of 0.10 - 0.15
mm (0.004 -0.006″), adjust the shims, 6, be-
8
tween the left and right axles to obtain the correct 9
6 6
free-play clearance.
7 5
4
1
5
6
3
2
21
25-21
5. Apply Prussian Blue to the pinion shaft gear 7. Inspect the gear tooth markings. If the markings
teeth. are incorrect, adjust the pinion gear assembly as
required to obtain the correct pattern as shown.
6. Rotate the pinion until the ring gear has rotated
one complete revolution.
Select the shims so that the Select the shims so that the ring
drive pinion is out nearer to the gear is put farther from the drive
ring gear. pinion.
Correct pinion gear to

ring gear tooth contact.
Select the shims so that the ring Select the shims so that the
gear is put nearer to the drive drive pinion is put farther from
pinion. the ring gear.
Ring Gear-To-Pinion Adjustment
22
25-22
Op. 25 108
GEAR REDUCTION BOX 1
Assembly 2
IMPORTANT: The oil seal, 1, is a cassette type seal
and must be installed in the hub cover, 2, using the
proper tools. If the proper tools are not used the seal
may fail prematurely.
NOTE: Install seal with metal side facing away from

the oil (towards outside of housing).
20002381
23
1. Lightly lubricate a new seal, 1, and install into the
hub cover, 2, using the special tool, 3, (NH
#NH00293, CIH #CAS2785).
NOTE: Seal driver set includes different sizes of
drive plates. For this application use the following:
• Handle 1
• Drive Plate -- 2-15/16 in.
3 2
• Drive Plate -- 2 in.
20002382
24
2. Position the wheel shaft outer bearing, 4, in the
cover, 5. 7
6
8 5
3. Install the seal, 6, and the hub and shaft assem-
bly, 7, in the cover, 5.
4. Position the two-piece locking ring, 3, in the shaft 3 2
groove.
5. Install the bevel gear, 2, on the shaft, making cer-
tain that the bevel gear counterbore hub fits down
fully over the locking ring, 3.
6. Install the inner bearing, 1, on the shaft.
4 1
25
25-23
7. Install the idler gear bearing, 3, and seal, 2, in the
drop box case, 4.
2
8. Install the final drive pinion gear, 5, bearing, 6,
and cover, 7, in the bottom of the drop box case, 3
4.
9. Install the idler shaft, 1, from the top.
26
25-24
RING GEAR-TO-PINION BACKLASH

Ring gear-to-pinion backlash must be checked and
adjusted whenever new components are used or if
the shim requirements are unknown.
NOTE: This is a continuation of the carrier bearing

preload adjustment.
1. Position the assembled axle housing assembly

in a vertical position, supported by the housing
and not the shaft.
NOTE: For personal safety, be sure the assembly is
properly supported to prevent falling.
2. Position the differential assembly in the housing,

being sure the differential case is fully seated in
the bearing and axle housing counterbore.
3. Install the bearings, 1 and 2, snap rings, 3, king-
pin, 4, O ring, 5, bearing, 6, and spacer, 7, into the 7
idler case, 8.
6
4. Position the idler gear, 9, inside the idler case, 8. 5
3 4
2 9
8 1
20000949
27
25-25
5. Position the idler gear case, 2, onto the drop box
case, 1. 8
5 6
6. Install the steering arm assembly, 3, onto the 3
idler gear case, 2. 7
7. Install the retaining bolts, 8, and tighten to the 4
specified torque. See “Bolt Torque Specifica-
tions”, discussed later in this section.
2
8. Install the pinion gear, 6, and bearing, 7, on the
axle shaft. Apply liquid gasket to the mating sur-
face of the axle housing, 4, and the idler gear
case, 2. 1
9. Lightly grease and position, the O ring, 5, in place
on the axle housing, 4, and install the drop box 28
assembly, 1, 2, and 3, to the axle housing, 4.
10. Install the drop box to axle housing retaining bolts
and tighten to the specified torque. See “Bolt
Torque Specifications”, discussed later in this
section.
11. Apply liquid gasket to the drop box cover mating
surface and install the cover and hub assembly
to the drop box case, 1.
12. Install the retaining bolts and tighten to the speci-
fied torque. See “Bolt Torque Specifications”, dis-
cussed later in this section.
BEVEL GEAR-TO-PINION BACKLASH

4
Check
With the front wheels removed and the front end of
the tractor supported, use the following steps to de-
termine the bevel gear-to-pinion gear backlash.
1. Remove the oil drain plug from the drop box case
and drain the oil into a suitable container. 1
2. Install a long bolt, 1, into the drain plug hole, until 5
it makes contact with the pinion gear, 2, and pre-
vents it from rotating. 3
2
3. Install a bolt, 5, in the wheel hub flange, 3, and at-
tach a dial indicator, 4. 29
4. Rotate the hub back and forth and observe the
dial indicator reading. Replace the bearings and/
or gears if the backlash exceeds 0.5 mm
(0.020″).
25-26
SECTION 27 - DIFFERENTIAL, REAR AXLE - CHAPTER 1
Chapter 1 - Differential, Rear Axle
CONTENTS

27 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
27 110 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
27 110 Differential Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
27 126 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
27 106 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
27 126 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
27 126 Final Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
27-1
SPECIFICATIONS
Differential Pinion Gear to Shaft Clearance

Std. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (.004″)
Max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 mm (.020″)
Differential Pinion Gear Thrust Washer Thickness
Std. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 mm (.047″)
Min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9 mm (.035″)
Differential Gear Thrust Washer Thickness (Side Gears)
Std. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm (.079″)
Min. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 mm (.067″)
Drive Pinion Pre-load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 -- 17 kg (28.6 -- 37.5 lbs.)
Drive Pinion and Ring Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 -- .18 mm
(00512″ -- .0071″)
0.4 mm (.0157″) max.
Differential Side Gear to Pinion Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 -- 0.15 mm
(.004″ -- .006″)
0.3 mm (0.12″) max.
Rear Axle Diameter
D35, DX35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.36″)
D40, DX40, D45, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 mm (2.56″)
27-2
Ring Gear Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-62.7 N⋅m (36.2-46.3 ft. lb.)
Differential Case Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49-62.7 N⋅m (36.2-46.3 ft. lb.)

4T, 4.8 3.6 -- 5.1 4.9 -- 6.9
M6 7T, 8T, 8.8 1.0 6.1 -- 8.3 8.3 -- 11.3 ------------ ------------ ------------
10T, 11T 8.6 -- 11.6 11.7 -- 15.7
4T, 4.8 9.4 -- 12.3 12.7 -- 16.7 11.2 -- 14.9 15.2 -- 20.2
M8 7T, 8T, 8.8 1.25 16.7 -- 21.0 22.6 -- 28.4 1.0 19.6 -- 25.3 26.5 -- 34.3
10T, 11T 21.0 -- 26.8 28.5 -- 36.3 22.4 -- 29.7 30.4 -- 40.2
4T, 4.8 18.8 -- 24.6 25.5 -- 33.3 21.0 -- 26.8 28.5 -- 36.3
M10 7T, 8T, 8.8 1.5 32.5 -- 41.3 44.1 -- 55.9 1.25 36.2 -- 46.3 49.0 -- 62.8
10T, 11T 39.8 -- 51.3 54.0 -- 69.6 42.7 -- 54.2 57.9 -- 73.5
4T, 4.8 27.5 -- 34.8 37.3 -- 47.1 31.8 -- 40.5 43.1 -- 54.9
M12 7T, 8T, 8.8 1.75 48.5 -- 61.5 65.7 -- 83.3 1.25 54.9 -- 69.4 74.5 -- 94.1
10T, 11T 68 -- 85.6 92 -- 116 73.1 -- 93.7 99 -- 127
4T, 4.8 46.3 -- 59.3 62.8 -- 80.4 51.4 -- 64.4 69.7 -- 87.3
M14 7T, 8T, 8.8 2.0 76.8 -- 97.4 104 -- 132 1.5 85.6 -- 109 116 -- 148
10T, 11T 102.6 -- 129 139 -- 175 110 -- 136 149 -- 185
4T, 4.8 63.5 -- 81.2 86 -- 110 67.2 -- 84.9 91 -- 115
M16 7T, 8T, 8.8 2.0 110 -- 136.5 149 -- 185 1.5 116 -- 142 157 -- 193
10T, 11T 151.3 -- 188 205 -- 255 162 -- 199 220 -- 270
4T, 4.8 83.4 -- 104 113 -- 141 96.7 -- 120 131 -- 163
M18 7T, 8T, 8.8 2.0 145 -- 174 196 -- 236 1.5 169 -- 206 230 -- 280
10T, 11T 203 -- 246 275 -- 333 220 -- 270 299 -- 367
4T, 4.8 106 -- 133 144 -- 180 126 -- 155 171 -- 211
M20 7T, 8T, 8.8 2.5 177 -- 214 240 -- 290 1.5 203 -- 245 275 -- 333
10T, 11T 268 -- 252 363 -- 341 293 -- 358 397 -- 485
SPECIAL TOOLS
Seal Driver Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NH #NH00293, CIH #CAS2785)

D35 Drive Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3.0″), (2-1/8″)
DX40, 45 Drive Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3-3/16″), (2-5/16″)
27-3
1 2
3
5
6
8 12
9
11
3
4 15
13 16
8 2
7 10 1
21
20
22 11
19
9
23 12
14
17
24
25
18
D35/DX35
20043765
1
1. Bearing Carrier 14. Differential Gear Case End Plate
2. Shims 15. Lock Plate
3. Retaining Ring 16. Bearing
4. Bearing 17. Differential Lock Shaft
5. Differential Lock Clutch 18. Differential Lock Pedal
6. Differential Gear Case 19. Return Spring
7. Drive Pinion and Ring Gear 20. Differential Lock Fork
8. Thrust Washer 21. Tension Spring
9. Side Gear 22. Inner Roll Pin
10. Differential Pinion Shaft 23. O ring
11. Pinion Gear 24. Differential Lock Shaft Seal
12. Thrust Washer 25. Roll Pin
13. Roll Pin
27-4
1 2
3
5
6 13
8
9 12
12
14 11 13
3 16
4
17
8 2
10
11
7 1
22 12
13
21 23 12
20
9
13
24 15
18
25
26
19
D40, DX40, D45, DX45

20000943
2
1. Bearing Carrier 14. Pinion Shaft Joint
2. Shims 15. Differential Gear Case End Plate
3. Retaining Ring 16. Lock Plate
4. Bearing 17. Bearing
5. Differential Lock Clutch 18. Differential Lock Shaft
6. Differential Gear Case 19. Differential Lock Pedal
7. Drive Pinion and Ring Gear 20. Return Spring
8. Thrust Washer 21. Differential Lock Fork
9. Side Gear 22. Tension Spring
10. Differential Pinion Shaft 23. Inner Roll Pin
11. Differential Pinion Shaft 24. O ring
12. Pinion Gear 25. Differential Lock Shaft Seal
13. Thrust Washer 26. Roll Pin
27-5
Op. 27 110
DIFFERENTIAL
The differential assembly consists of a drive pinion,
a ring gear, differential pinion gears, axle side gears,
and a differential lock, housed in the differential case.
Power is transmitted by the transmission to the
differential drive pinion and ring gear. The ring gear
is bolted to the differential case, which contains the
differential pinion gears, and the axle side gears.
As the differential case rotates, the differential pinion

gears rotate and drive the two axle side gears. The
final drive pinions are splined to the side gears and
mesh with the final drive gear. As the final drive
pinions rotate with the differential assembly, power is
transmitted to the final drive gears and rear axles.
A front wheel drive output dropbox assembly is

mounted to the bottom of the differential case on
tractors equipped with the front wheel drive option.
The front wheel drive gears and the output shaft, are
driven by a pinion gear located on the pinion shaft.
The front wheel drive is operated by a control lever
on the left control pod of the deluxe model tractors,
and by a control lever located to the left of the seat on
the economy model tractors.
Op. 27 110
DIFFERENTIAL LOCK
A differential lock is provided to lock the differential
system, so that both rear wheels are driven by the
differential gears, even when one wheel loses
traction. The differential lock control pedal is foot
operated and is located on the left side of the tractor
deck on the deluxe model tractors, 1, and on the right
side of the deck on the economy model tractors, 2.
Depressing the pedal rotates the shaft and the 1

actuating pin, causing the change fork to move 10998223
toward the differential assembly, and at the same
time, compresses the return spring. This causes the 3
coupler to move toward the differential. The lugs on
the coupler, index with the holes on the differential
gear case. Continued pressure on the foot pedal will 2
lock the side gear to the differential case. When the
foot pedal is released, the return spring moves the
change fork and the sliding coupler away from the
differential case, disengaging the differential lock.
30997547
27-6
Op. 27 126
REAR AXLE
4 6
5 2
1
1. Ring Gear and Pinion-Primary Reduction The rear axle used on the D35, DX35, D40, DX40,
2. Final Drive Pinion and Gear-Secondary Reduction D45 and DX45, is a double reduction type, consisting
3. Differential Pinion of a conventional ring gear and pinion for primary
4. Differential Ring Gear reduction, and a final drive pinion and gear for
5. Final Drive Pinion secondary reduction.
6. Final Drive Gear
7. Rear Axle Shaft The axle housing encloses the brake discs and
stators. The rear axle and differential components
are lubricated by the common hydraulic oil reservoir.
27-7
OVERHAUL
Op. 27 106
DIFFERENTIAL
Removal
To remove the differential from the housing, the
hydraulic PTO clutch, and shafts, must be removed
first. To accomplish this the differential housing must
be separated from the transmission, see Section 21
for separating the 12 x 12 transmission, and see
Section 29 for separating the HST transmission. For
removal of the PTO clutch and shafts, see “PTO”,
Section 31.
1. Remove the lower lift links from the rear axles.

2. Disconnect the brake control rods, 1, from the
brake control levers, 2. 2
6
3. Attach a suitable overhead lifting device, 1, to the
rear axle assembly, 2, and remove the axle 1
housing retaining bolts. 2
WARNING
The axle housing is difficult to balance. Use
caution during removal to avoid personal injury.
4. Separate the axle assembly from the differential

housing and use the lifting device to move the
axle assembly out and away from the differential
housing.
5. Repeat steps 1 through 4 for the opposite side of
the tractor. 7
6. Remove the hydraulic lift cover from the
differential housing, see “Hydraulics”, Section
35.
27-8
7. Remove the differential lock pedal, 1, from the
4 3 5
differential housing, 2.
6
8. Remove the tension spring, 3, from the
8
differential lock fork, 4, and the roll pin, 5.
9
9. Remove the roll pin, 5, from the differential lock
shaft, 6. 1 9
10. Remove the retaining roll pin, 7, from the
differential lock shaft, 6.
11. Pull the differential lock shaft, 6, from the
differential lock fork, 4, and the differential
housing, 2. 20000938 2 7
12. Remove the return spring, 8, from the differential 8
lock shaft, 6.
13. Remove the differential lock fork, 4, from the
14. Remove and discard the differential lock shaft
seals, 9, from the differential housing, 2.
15. Remove the PTO clutch and shafts from the
differential housing to gain access to the
differential assembly, see “PTO”, Section 31 for
removal procedure.
16. Loosen and remove the four retaining bolts, 1,
securing the left side differential bearing carrier, 3,
to the differential housing, 4. Note the number,
and thickness of the shims, 2, between the
bearing carriers, 3, and the differential housing, 4,
for ease of assembly. Remove the bearing carrier,
3, from the differential housing. Repeat for the 3
right side.
4 2
20003041
9
17. Carefully lift the differential assembly from the
top of the differential housing.
30000411
10
27-9
7
7
3 2 15
13 11 9
15 14
10
6
8
9
4
5
1
6 9
12 7
7
20000937
11
1. Retaining Bolt 9. Differential Pinion Gear
2. Differential Gear Case End Plate 10. Side Gear
3. Differential Gear Case 11. Thrust Washer
4. Side Gear 12. Ring Gear
5. Thrust Washer 13. Differential Lock Clutch
6. Differential Pinion Shaft 14. Retaining Ring
7. Thrust Washer 15. Differential Carrier Bearing
8. Pinion Joint
Disassembly Inspection
1. Loosen and remove the gear case end plate 1. Clean all parts in a suitable solvent and allow to
retaining bolts, 1. air dry.
2. Separate the end plate, 2, from the differential 2. Inspect side gear teeth for excessive wear or
gear case, 3. damage.
3. Remove the differential side gear, 4, and thrust 3. Measure the thickness of the differential gear
washer, 5. thrust washers. Replace the washers that
measure less than the minimum thickness.
4. Remove the differential pinion shafts, 6, thrust
washers, 7, pinion joint, 8, and the pinion gears, 4. Inspect the differential pinion gears and shafts for
9, from the gear case, 3. excessive wear or damage.
NOTE: The D35 and DX35 have one differential 5. Inspect the differential gear case and end plate
pinion shaft, 6, two thrust washers, 7, and two for wear or damage.
differential pinion gears, 9. The D40, DX40, D45 and
DX45 use three differential pinion shafts, 6, four thrust
washers, 7, and four differential pinion gears, 9.
5. Remove the remaining side gear, 10, and thrust

washer, 11, from the gear case, 3.
27-10
Assembly
1. Install the thrust washer, 11, and the side gear,
10, into the differential gear case, 3.
2. Assemble the differential pinion shafts, 6, thrust
washers, 7, pinion joint, 8, and the pinion gears,
9, into the gear case, 3.
3. Install the remaining side gear, 4, and thrust
washer, 5, into the gear case, 3.
4. Install the ring gear, 12, and the differential gear
case end plate, 2, onto the gear case, 3, and
5. Tighten and torque the differential gear case
retaining bolts to specified torque.
Installation
1. Carefully lower the differential assembly into the
2. Install the shims and the bearing carriers onto the
3. Secure with the four retaining bolts. Tighten and
torque the retaining bolts to specified torque.
4. Install the PTO clutch and any PTO shafts that
were removed to gain access to the differential.
See Section 31, “PTO” for the installation
procedure.
30000411
12
5. Lubricate new differential lock shaft seals, 9, with
petroleum jelly, and install in the differential
4 3 5
housing, 2. 6
8
6. Install the differential lock fork, 4, onto the
differential lock clutch. 9
7. Install the differential lock shaft, 6, through the 1 9
differential housing, 2, and the differential lock
fork, 4.
8. Install the differential lock return spring, 8, on the
differential lock shaft, 6.
9. Compress the differential lock return spring, 8, 20000938
2 7
D35, D40, D45
and install the roll pin, 5, into the differential lock
shaft, 6. 13
27-11
10. Install the outer roll pin, 7, into the differential lock
shaft, 6.
11. Install the tension spring, 3, onto the roll pin, 5,
and the differential lock fork, 4.
4
12. Install the differential lock pedal, 1, onto the 1
differential housing, 2, and the differential lock 6
shaft, 6. 7
13. Install the hydraulic lift cover onto the differential 8
housing. See Section 35, Hydraulics.
9
3 5
2
9
DX35, DX40, DX45
20002391
14
rear axle assembly, 2, and position the axle 1
housing on the differential housing. Be sure to 2
align the mounting holes and the final gear and
the final pinion with the housing.
WARNING
caution during installation to avoid personal
injury.
15. Install and tighten the axle housing retaining

bolts.
16. Install the wheels and the fenders onto the 15
tractor.
27-12
17. Connect the brake control rods, 1, to the brake
control levers, 2.
2
18. Install the lower lift links to the rear axles.
19. Fill the combined transmission, rear axle, and
hydraulic reservoir with clean Hy-Tran Ultra
hydraulic oil.
20. Install the ROPS onto the tractor. 1
21. Install the fuel tank onto the tractor.
16
DRIVE PINION
Removal
NOTE: See “Differential Overhaul-Removal”, for the
procedure to remove the differential, to allow access
to the drive pinion.
Disassembly
1. Loosen and remove the locking collar, 1, on the 1
drive pinion shaft, 2. 2
NOTE: Steps 2, 3, and 4 apply to tractors equipped
with the FWD option. The 2WD does not use the fixed
gear or the retaining ring.
20000939
17
2. Slide the drive pinion shaft, 1, towards the rear of
the differential housing to gain access to the
retaining ring, 2, that secures the fixed gear, 3, on 3
the drive pinion shaft, 1.
1
3. Remove the retaining ring, 2.
20000940
18
27-13
4. Remove the fixed gear, 1, the retaining ring, 2,
the locking collar, 3, and the tapered roller
bearing, 4, from the drive pinion shaft, 5. 7 6 5 4 3 1 2
5. Remove the drive pinion shaft, 5, the shim, 7,
(if used), and the remaining tapered roller
bearing, 6, from the differential housing.
20000941
19
Inspection
1. Clean all parts in a suitable cleaning solvent and
allow to air dry.
2. Turn the tapered roller bearings by hand to check
for roughness. Replace as necessary.
3. Inspect the drive pinion shaft for excessive wear,
nicks, chips or other damage. Replace as
necessary.
4. Inspect the fixed gear for excessive wear, nicks,
chips or other damage. Replace as necessary.
Assembly
NOTE: Replacement ring and pinion uses the
original shim packs. There is no tolerance number 7 6 5 4 3 1 2
stamped on the replacement parts.
1. Assemble the shim, 7, (if used), and the rear,

tapered roller bearing, 6, on the drive pinion shaft,
5.
NOTE: The 2WD does not use the fixed gear or the
retaining ring.
2. Install the drive pinion shaft, 5, from the rear of

the differential housing while installing the front, 20000941
tapered roller bearing, 4, the locking collar, 3, and 20
the fixed gear, 1, (if equipped with FWD). Install
a new retaining ring, 2, on the pinion shaft, 5, to
secure the fixed gear, 1, (if equipped with FWD).
NOTE: Turn the drive pinion shaft several turns by
hand before performing the pull-scale test.
27-14
3. Adjust the pinion bearing pre-load (rolling
torque), by wrapping a strong cord, 1, around the 3
pinion shaft, 2.
4. Attach the opposite end of the cord to a pull scale,
3.
5. Tighten the locking collar, 4, while pulling on the
pull scale, until a constant pull of 13 - 17 Kg
(28.6 - 37.5 lbs.) is required rotate the drive
pinion shaft, 2. 1
6. When the proper rolling torque is achieved, stake
the locking collar, 4, to maintain the adjustment.
7. Install the differential into the differential housing
and secure with the right and left bearing carriers.
See “Overhaul - Differential-Installation”.
8. If new differential components are used, adjust
the backlash, and the ring gear contact pattern as
follows:
2
4
20000942
21
-- Place a dial indicator, 1, at a right angle to the
top of one ring gear tooth, 2. 1
-- Rock the ring gear, 2, back and forth and
observe the reading on the dial indicator, 1.
-- Adjust the shims to obtain the correct 2
backlash. See “Specifications”.
22
27-15
Select the shims so that the Select the shims so that the
drive pinion is out nearer to the ring gear is put farther from the
ring gear. drive pinion.
Correct pinion gear to

ring gear tooth contact.
Select the shims so that the ring

Select the shims so that the
gear is put nearer to the drive
drive pinion is put farther from
pinion.
the ring gear.
23
-- Using Prussian Blue on the pinion gear teeth,
rotate the pinion gear, and check the gear
tooth contact pattern.
-- Adjust the pinion shims and the differential
shims to obtain the correct tooth contact
pattern.
9. See “Overhaul - Differential-Installation”, for the

remainder of the differential installation.
27-16
Op. 27 126
REAR AXLE
Removal
1. Drain and remove the fuel tank from the tractor.
2. Remove the ROPS from the tractor.
NOTE: On the DX35, 40 and 45 tractors, removal of
the seat and the deck may be necessary.
3. Remove the wheels and the fenders from the

tractor.
4. Drain the oil from the combined transmission,
rear axle, and hydraulic reservoir into a suitable
container.
24
WARNING

housing.
25
27-17
Disassembly
1. Use a suitable puller, 1, to remove the inner axle 2
bearing, 2, from the axle, 3.
1
3
30000160
26
2. Use a suitable puller, 1, to remove the inner final
pinion bearing, 2, from the pinion shaft.
2
30000161
27
3. Remove the large final gear, 1, from the axle
shaft, 2.
2
30000162
28
27-18
4. Remove the split clip, 1, from the axle shaft, 2.
30000163
29
5. Loosen and remove the four retaining bolts, 1,
holding the axle shaft retainer, 2, to the axle case,
3. 3
1 2
30000164
30
6. Use a hammer and an aluminum or brass drift to
tap the axle shaft, 1, out of the axle case, 2. 2
NOTE: It may be necessary to use a press to remove
the axle shaft from the axle case.
30000165
1
31
27-19
7. Remove the axle shaft, 1, from the axle case, 2.
2 1
30000166
32
8. Remove the remaining axle bearing, 1, from the
axle case, 2. 2
30000167
1
33
9. Gently tap the axle shaft retainer, 1, off of the axle
shaft, 2. 1 2
30000168
34
27-20
10. Remove and discard the oil seal, 1, from the axle
shaft retainer, 2. 2
30000169
35
11. Use a hammer and an aluminum or brass drift to
tap the outer axle shaft bearing, 1, out of the axle
case, 2.
1
30000170/30000171
36
Inspection
1. Clean the axle components with a suitable
2. Rotate the bearings by hand to check for
roughness or binding. Check the bearings for
excessive wear or damage, and replace if
necessary.
3. Inspect the final reduction gear teeth for excess
wear or damage. Repair or replace as necessary.
4. Inspect the axle shaft for nicks, scratches or
other damage. Repair r replace as necessary.
5. Inspect the axle case for cracks or other damage.
27-21
Assembly
1
1. Install the outer axle shaft bearing, 1, into the axle
case, 2. 2
30000171
37
2. Install the inner axle shaft bearing, 1, into the axle
case, 2. 2
1
30000167
38
NOTE: Different drive plates, 2 and 3, are used for
the D35 and the D40, 45.
3. Assemble the special installation tool, from the

seal installer kit # (NH #00293, CIH #CAS2785).
Use handle, 1, drive plate, 2, drive plate, 3, and
secure with the supplied retaining screw, 4.
TOOL CHART
1
Model Tool No. Size 4
3
DX35 1. Handle 2
2. Plate 3.0″ 20002392
3. Plate 2-1/8″ 39
4. Screw
D40, DX40 1. Handle
D45, DX45 2. Plate 3-3/16″
3. Plate 2-5/16″
4. Screw
27-22
NOTE: The orientation of the axle seal, 1, in the axle
shaft retainer, 2, is such that the rubber side of the 2
seal faces inward and the metal side of the seal faces
outer side of the axle shaft retainer.
30000169
40
4. Install a new axle seal into the axle shaft retainer,
1, using the special seal driver tool, 2.
20002393
41
5. Lubricate the new seal with petroleum jelly and
slide the axle shaft retainer, 1, onto the axle, 2. 1 2
30000172
42
27-23
6. Install the axle shaft, 1, into the axle case, 2.
2 1
30000166
43
7. Install the split clip, 1, onto the axle shaft, 2.
30000163
44
8. Install the four retaining bolts, 1, and lockwash-
ers, 2, through the axle shaft retainer, 3, and into 3 2
4
the axle case, 4. Tighten the bolts, 1. 1
30000173
45
27-24
9. Install the final reduction gear, 1, onto the axle
shaft, 2. 1
10. Install the inner axle bearing, 3, onto the axle
shaft, 2.
2 3
30000174
46
11. Install the final pinion bearing, 1, onto the pinion
shaft, 2. 1
2
30000175
47
housing on the differential housing. Be sure to 2
WARNING
injury.

bolts.
14. Install the wheels and the fenders onto the 48
tractor.
27-25
control levers, 2. 2
hydraulic oil.
49
Op. 27 126
FINAL PINION
Removal
1. Drain and remove the fuel tank from the tractor.
2. Remove the ROPS from the tractor.
NOTE: On the DX35, 40 and 45 tractors, removal of
the seat and the deck may be necessary.
3. Remove the wheels and the fenders from the

tractor.
4. Drain the oil from the combined transmission,
rear axle, and hydraulic reservoir into a suitable
container.
50
27-26
WARNING

housing.
51
Disassembly
NOTE: The brakes may be serviced with the axle
case attached to the differential housing, but if final
pinion service is required, the axle case must be
removed from the differential housing.
1. Loosen and remove the retaining nut, 1, on the
brake lever, 2. Remove the brake lever, 2, from
the brake cam.
30000177 2
52
2. Loosen and remove the brake cover retaining
bolts, 1. 1
30000178
53
27-27
3. Remove the brake cover assembly, 1, from the
axle housing, 2 2
30000179
54
4. Remove and discard the brake cam, oil seal, 1,
from the brake cover, 2. 2
30000182
55
5. Remove the stators, 1, and the brake discs, 2,
from the final pinion shaft, 3. 3
1
30000183
56
27-28
NOTE: If the final pinion support bearing, 1, is to be
removed, the large final gear, 2, and the inner
bearing, 3, on the axle shaft must be removed first.
3
30000185
2
57
6. Using a hammer and a brass or aluminum drift,
lightly tap the final pinion shaft, 1, from the axle 3
housing, 2.
7. Remove the final pinion support bearing, 3, from
the axle housing, 2.
2
30000184 1
58
Inspection
1. Clean all parts in a suitable solvent and allow to
air dry.
2. Inspect the bearings for roughness by turning
them by hand. Replace if necessary.
3. Inspect the final pinion shaft for marks or other
damage. Replace if necessary.
4. Inspect the brake cover for damage or cracks.
Repair or replace as necessary.
27-29
Assembly
1. If removed during disassembly, install the final
3
pinion support bearing, 3, into the axle housing,
2.
2. Install the final pinion shaft, 1, into the axle
housing, 2. 2
30000184
1
59
3. Install the stators, 1, and the brake discs, 2, onto
the final pinion shaft, 3. 3
30000183
1
60
4. Lubricate a new brake cam, oil seal, 1, with
petroleum jelly, and install into the brake cover, 2. 2
30000182
61
27-30
5. Install the brake cover assembly, 1, onto the axle
housing, 2. 2
30000179
62
6. Install and tighten the brake cover retaining bolts, 1.
1
30000178
63
7. Install the brake lever, 2, onto the brake cam, and
secure with the retaining nut, 1. Tighten the
retaining nut, 1.
30000177
2
64
27-31
Installation
1
housing on the differential housing. Be sure to
WARNING
injury.

bolts. 65
3. Install the wheels and the fenders onto the
tractor.
control levers, 2. 2
hydraulic oil.
66
27-32
SECTION 29 -- HYDROSTATIC TRANSMISSION -- CHAPTER 1
Chapter 1 -- Hydrostatic Transmission
CONTENT

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
High Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Forward Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Reverse Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
29 212 Variable Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
29 212 Two Position Displacement Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
29 134 Hi/Lo Speed Control/Control Pod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hi/Lo Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
29 200 Foot Control Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Charge Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Testing and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hi/Low Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Separating the Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DX35, DX40, and DX45 w/HST Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Separating at the HST Housing/Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Separating the HST Housing at the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Attaching the HST Housing to the Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Attaching the HST to the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
29 202 Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
29-1

29 130 Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Motor Swash Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Input and Output Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pump Swash Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
29 130 Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Swash Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Pump Shaft (Input Shaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
29 218 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Assembly for Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Motor Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
29 218 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly for Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Port Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
29 130 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Hydrostatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
29-2

29 204 Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Description of Operation -- Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
29 300 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Gearbox Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Overhaul -- Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
29 214 Hi/Lo Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Adapter Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Electromagnet Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
29-3
SPECIFICATIONS
Hydrostatic Transmission
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kayaba Industry Co. Ltd., Japan
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HVFD-28C37-M
Theoretical Displacement of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 28.1 cm3/rev.
Theoretical Displacement of the Motor
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 37.2 cm3/rev.
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 22.0 cm3/rev.
Theoretical Displacement of the Charge Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 cm3/rev.
Maximum Input Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2700 rpm
Maximum Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 bar (5000 psi)
Output Speed
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 1950 rpm (at 97 bar [1400 psi])
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 - 3328 rpm
Output Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 N⋅m (44 ft. lbs.) at 245 bar (3550 psi)
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 12 bar (114 - 170 psi) at 2600 rpm
Swash Plate Tilt Angle (Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ± 17.8°
Swash Plate Tilt Angle (Motor)
Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.0°
High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0°
Operating Moment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum 16 N⋅m (12 ft. lbs.) at 3000 psi
Hydraulic Tests
NOTE: Warm the oil to 25° - 50° C (80° - 120° F) before performing any hydraulic test.
High Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 bar (5000 psi) at 16 min.

Charge Pump Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.86 - 11.72 bar (114 - 170 psi) at 2600 rpm
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 bar (17.5 psi) pressure differential
Torque Specifications
Hydrostatic Transmission Cover Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2.5 N⋅m (1.4 - 1.9 ft. lbs.)
Charge Pump Housing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6 N⋅m (13 ft. lbs.)
HST Port Block Retaining Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70.6 N⋅m (52 ft. lbs.)
Transmission housing with rear axle (buckle-up bolts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 N⋅m (60 ft. lbs.)
Check and High Pressure Relief valve Retaining Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63.7 N⋅m (47 ft. lbs.)
High and Low speed Control Spool Retaining Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 N⋅m (37.6 ft. lbs.)
Swash plate Cover Retaining Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 N⋅m (5.1 ft. lbs.)
High Pressure Relief valve Inspection Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.4 N⋅m (21.7 ft. lbs.)
High Pressure Relief valve Inspection plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.7 N⋅m (10.8 ft. lbs.)
HST Foot Control Pedals (Neutral Gear)

Forward Pedal Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 - 23 mm (0.866″ - 0.905″)
Reverse Pedal Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.5 - 28.5 mm (1.08″ - 1.12″)
Spring
Length (Hook to Hook) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm ± 2.0 mm (4-11/16″ ± 5/64″)
Cruise Control Magnet to Transmission Pivot WA Plate . . . . . . . . . . . . . . . . . . . . 0.5 - 1.5 mm (0.020″ - 0.060″)
29-4
DX35/DX40/DX45 Transmission Speeds
Forward Speeds With AG 13.6-24 With AG 14.9-24 With R4 17.5L-24 With Turf
Tire Tire Tire 44x18.0-20 Tire
I Range Low 5.61 kph (3.49 mph) 5.89 kph (3.66 mph) 5.69 kph (3.53 mph) 5.06 kph (3.14 mph)
I Range High 9.49 kph (5.9 mph) 10.0 kph (6.21 mph) 9.62 kph (6.0 mph) 8.56 kph (5.32 mph)
II Range Low 13.0 kph (8.20 mph) 13.6 kph (8.45 mph) 13.1 kph (8.14 mph) 11.7 kph (7.27 mph)
II Range High 21.9 kph (13.6 mph) 23.0 kph (14.3 mph) 22.2 kph (13.8 mph) 19.8 kph (12.3 mph)
NOTE: Reverse has same speed capability as forward and depends on stop setting. Theoretical stop
setting is at 75% of forward.
29-5

4T, 4.8 2.8 - 4.0 3.8 - 5.4
M5 7T, 8T, 8.8 0.70 4.9 - 6.9 6.9 - 9.3 ----------- ------------ ------------
10T, 10.9, 11T 6.7 - 9.4 9.0 - 12.7
4T, 4.8 3.6 - 5.1 4.9 - 6.9
M6 7T, 8T, 8.8 1.0 6.1 - 8.3 8.3 - 11.3 ----------- ------------ ------------
10T, 10.9, 11T 8.7 - 11.6 11.8 - 15.7
4T, 4.8 9.4 - 12.3 12.7 - 16.7 11.2 - 14.8 15.2 - 20.1
M8 7T, 8T, 8.8 1.25 16.6 - 21.0 22.6 - 28.4 1.0 19.5 - 25.3 26.5 - 34.3
10T, 10.9, 11T 21.0 - 26.8 28.4 - 36.2 22.4 - 29.7 30.4 - 40.2
4T, 4.8 18.8 - 24.6 25.5 - 33.3 21.0 - 26.8 28.4 - 36.3
M10 7T, 8T, 8.8 1.5 32.5 - 41.2 44.1 - 55.9 1.25 36.2 - 46.3 49.0 - 62.8
10T, 10.9, 11T 39.8 - 51.4 53.9 - 69.9 42.7 - 54.2 57.9 - 73.5
4T, 4.8 27.5 - 34.7 37.3 - 47.1 31.8 - 40.5 43.1 - 54.9
M12 7T, 8T, 8.8 1.75 48.5 - 61.5 65.7 - 83.4 1.25 55.0 - 69.4 74.5 - 94.1
10T, 10.9, 11T 68.0 - 85.4 92.9 - 116 73.1 - 93.3 99.0 - 127
4T, 4.8 46.3 - 59.3 62.8 - 80.4 51.4 - 64.4 69.6 - 87.3
M14 7T, 8T, 8.8 2.0 76.7 - 96.9 104 - 131 1.5 86.1 - 109 117 - 148
10T, 10.9, 11T 102 - 129 139 - 175 108 - 137 147 - 186
4T, 4.8 63.6 - 81.0 83.3 - 110 67.3 - 84.6 91.3 - 115
M16 7T, 8T, 8.8 2.0 110 - 136 149 - 184 1.5 116 - 142 157 - 192
10T, 10.9, 11T 152 - 188 206 - 255 163 - 199 221 - 270
4T, 4.8 106 - 132 144 - 179 127 - 156 172 - 211
M20 7T, 8T, 8.8 2.5 177 - 213 240 - 289 1.5 203 - 246 275 - 333
10T, 10.9, 11T 268 - 325 363 - 441 293 - 358 397 - 485
SPECIAL TOOLS
Gauge -- (6000 psi) OEM 1464
Gauge -- (300 psi) OEM 1457
HST High Pressure Test Fitting NH #CNH299007, CIH #CAS2787
HI/LOW Pressure Test Fitting NH #FNH00011, CIH #CAS2791
29-6
10
3
6
9
5 2
7 8
30003091
1
1. Hydrostatic transmission 6. Oil cooler
2. Rear transmission reservoir 7. Oil cooler outlet hose
3. Hydraulic suction filter 8. HST inlet oil line
4. Hydraulic pump 9. HST pedal assembly
5. Oil cooler inlet hose
Op. 29 202
The hydrostatic transmission assembly, 1, consists NOTE: If the oil cooler circuit is restricts the flow from
of a gerotor type charge pump, a variable the charge pump, a by pass valve located in the HST
displacement piston type hydraulic pump and a two- filter base will open, the oil flow will by pass the cooler
speed piston type hydraulic motor, which are located but will still be filtered by the HST filter, before
in the transmission clutch housing. The hydrostatic entering the HST assembly.
transmission is driven by an adapter plate that is
bolted to the engine flywheel. The charge pump After the oil is filtered the oil enters the hydrostatic
circuit is supplied with oil from the rear transmission pump via line, 9. The pump supplies oil to the
reservoir, 2, and is filtered by the hydraulic suction hydrostatic motor that drives the transmission
filter, 3, before entering the charge pump. The charge gearbox.
pump shares the rear transmission reservoir and
hydraulic suction filter with the hydraulic system Forward and reverse motion is controlled by pedal
pump, 4. The output from the charge pump is routed assembly, 10.
by outlet line, 5, to the oil cooler, 6, oil then exists the
oil cooler by outlet hose, 7 and is routed to the HST
filter, 8.
29-7
1 2 9 10
11
3
4 5 8 12
6
7
20000743
2
POWER FLOW
High Range
Power flow as follows:

1. Engine adapter plate 7. Lower 20-tooth counter shaft gear
2. Input shaft 8. Mid 21-tooth counter shaft gear
3. Input shaft splined coupler 9. Upper front 26-tooth fixed gear
4. Input shaft hydrostatic transmission 10. Upper mid 31-tooth fixed gear
5. Output shaft hydrostatic transmission 11. 29-tooth high range gear and coupler
6. Output shaft splined coupler 12. Output to rear pinion and FWD drop box
29-8
1 9
2 10
3
12
4
5 8 11
6
7
20003052
Low Range
Power flow as follows:

1. Engine adapter plate 7. Lower 20-tooth counter shaft gear
2. Input shaft 8. Mid 21-tooth counter shaft gear
3. Input shaft splined coupler 9. Upper front 26-tooth fixed gear
4. Input shaft hydrostatic transmission 10. Upper rear 19-tooth fixed gear
5. Output shaft hydrostatic transmission 11. 41-tooth high range gear and coupler
6. Output shaft splined coupler 12. Output to rear pinion and FWD drop box
29-9
8
17 7
9
12
10 15
13
6
4
“B”
“A”
“A”
“B”
2 14 16
11
3 1
-- Charge Pressure
-- Suction
30003048
NEUTRAL POSITION
4
1. Reservoir 10. Hydrostatic pump
2. Suction screen 11. Hydrostatic motor
3. Hydraulic filter 12. Forward high pressure relief valve
4. Charge pump 13. Reverse high pressure relief valve
5. HST oil cooler 14. Hi/Low piston
6. Cooler bypass valve 15. Hi/Low solenoid valve
7. HST oil filter 16. Hi/Low shift spool
8. Check valve “A” 17. Charge pump relief valve
9. Check valve “B”
OIL FLOW then returns to sump via the charge pump relief
valve, 17.
Neutral Position
Oil is drawn from the transmission reservoir, 1, The charge pump relief valve, 17, maintains 7.86 –
through the suction screen, 2, and hydraulic filter, 3, 11.72 bar (114 – 170 psi). Pressure to the check
by the rotor type charge pump, 4. The pressurized oil valves 8 and 9 at all times. Oil flow past the check
flows from the charge pump to the oil cooler, 5, and valves pressurizes the passages “A” and “B” and the
then to the HST filter, 7. If the cooler will not allow flow pump and motor cylinder blocks.
through it, the cooler by pass valve, 6, will open and
the oil flow will by pass the oil cooler but still flow Because of equal pressures in passages “A” and “B”
through the HST filter, 7. From the HST filter the oil the motor does not rotate.
flows to both check valve, 8, and check valve, 9, and
29-10
5
8
17 7
9
15 12
10 13
6
4
“B1”
“A1”
“A2”
“B2”
2 14 16
11
-- Charge Pressure
3 1
-- High Pressure
FORWARD POSITION -- Suction

30003049
5
Forward Position back to the hydrostatic pump, 10, through passage

When the hydrostatic piston pump, 10, is rotating and “B1” to complete the cycle. When fluid leakage in the
the forward pedal is depressed, moving the pump system causes a drop in pressure on the suction
cam--plate from neutral, oil flows from the piston pump, passage “B1” below 6.4 – 8.3 bar (92 -- 120 psi) check
through passage “A”. Pump pressure on the back of valve, 9, opens and provides make--up fluid from the
the check valve, 8, closes the check valve and charge pump to replenish the oil in the low pressure
pressure increases in passage “A1”. All fluid from side of the loop. Excess fluid from the charge pump is
passage “A1” flows to the hydrostatic motor, 11, returned to the sump via the charge pump relief valve,
through passage “A2” causing the motor to rotate and 17.
moves the unit forward. When the forward pedal is
depressed further the increased oil flow rotates the The high pressure relief valve, 12, protects the
motor faster increasing wheel speed. Fluid discharged motor, 11, opening when pressure is above 345 bar
from the hydrostatic motor at B2 into passage “B” flows (5000 psi).
29-11
5
8
17 7
9
15 12
10 13
6
4
“B1”
“A1”
“A2”
“B2”
2 14 16
11
3 1 -- Charge Pressure
-- High Pressure
30003050 REVERSE POSITION -- Suction
6
Reverse Position into passage into passage “A” flows back to the
When the hydrostatic piston pump, 10, is rotating and hydrostatic pump, 10, through passage “A1”, to
the reverse pedal is depressed, moving the pump complete the cycle. When fluid leakage in the system
cam--plate from neutral, oil flows from the piston causes a drop in pressure on the suction passage
pump, through passage “B”. Pump pressure on the “A1” below 6.4 – 8.3 bar (92--120 psi) check valve, 8,
back of the check valve, 9, closes the check valve opens and provides make--up fluid from the charge
and pressure increases in passage “B1”. All fluid pump to replenish the oil in low pressure side of the
from passage “B1” flows to the hydrostatic motor, 11, loop. Excess fluid from the charge pump is returned
through passage “B2”, causing the motor to rotate to the sump via the charge pump relief valve, 17.
and moves the unit rearward. When the reverse
pedal is depressed further the increased oil flow The high pressure relief valve, 13, protects the
rotates the motor faster increasing wheel speed. motor, 11, opening when pressure is above 345 bar
Fluid discharged from the hydrostatic motor at “A2” (5000 psi).
29-12
Op. 29 212
VARIABLE DISPLACEMENT PUMP

The cylinder block, 3, and pistons, 4, are splined to 4 5
the input shaft, 1, and rotate with the shaft. In the
neutral position, the swash plate, 2, is in the vertical 2
position, at right angle to the pistons and the pistons
do not stroke. When in neutral position, the A
displacement in the cylinders, “A” and “B” are equal
and no fluid flows through the pump or motor valve
port plate, 5.
B
7
When the swash plate is tilted at an angle, 1, fluid in
the cylinder in position “A” is discharged out through
port, 2, in the valve plate, 3, as the cylinder is rotated
to position “B”. Maximum fluid flow is obtained when 1
the swash plate is at maximum tilt angle. A
2
29-13
Op. 29 212
1
15°
TWO POSITION DISPLACEMENT MOTOR
9°
The two-position displacement motor assembly has
a displacement of 15° and 9°, at 1, for low
transmission and high transmission operation
respectively. Displacements are obtained by the
raising and lowering of two pistons, 2, with the flow
of fluid pressure in line, 3.
3
20000775
9
29-14
Op. 29 134
3
HI/LO SPEED CONTROL/CONTROL POD 1
The speed control switch, 1, is located on the
right-hand control pod. It has two positions. The
“Turtle” (Lo) position operates the HST unit at below
normal speed. The “Rabbit” (Hi) position operates
the HST unit at above normal speed. The Hi/Lo
speed control can be operated with both ranges of
the transmission.
10998318
10
HL/LO SPEED CONTROL
1
Optional Hi/low speed control is located on the front
remote control valve joystick handle. Press the
“Rabbit”, 1, for high range or the “Turtle”, 2, for low
range.
NOTE: When the tractor is shut off, Hi/Lo defaults to

Low.
2
10998370
11
Op. 29 200
1
FOOT CONTROL PEDALS
The hydrostatic unit is operated by two-foot control 2
pedals; pedal, 1, for forward operation and pedal, 2,
for reverse operation. The foot pedals automatically
return to neutral (stopped) position when released.
The speed is controlled by varying the amount of
movement of the pedal from neutral position. When
a constant forward speed is desired on level terrain,
setting the speed control (cruise) switch, 3 (Figure
10), to the “SET” position will hold the foot pedal in the
fixed position and permit the operator to remove his
10997818
foot from the pedal. When the speed (cruise) control
switch is “RELEASED” the foot pedal automatically 12
returns to the neutral position and the tractor stops.
NOTE: The operator can depress the pedal further

from the set position to travel at a faster speed
momentarily. The pedal (cruise) control can also be
set in reverse.
29-15
2 3 4
6
1
5
7
9 8
A
10 11 A
7
“LOW” OR TURTLE POSITION

20000744
13
1. Hydraulic suction filter 7. Oil passage
2. HST charge pump 8. Hi/Low spool (located in HST center valve section)
3. Oil cooler 9. Piston
4. HST oil filter 10. Cylinder
5. Solenoid valve 11. Motor swash plate
6. Hi/Low switch
When the Hi/Low switch, 6, is moved to the low or piston cylinders, 10, is forced out of the cylinders by
turtle position, electrical current is not supplied to the the swash plate, 11, pushing on the pistons, 9, this oil
solenoid valve, 5. Without current supplied, the is returned to sump via the Hi/Low spool, 8. The
solenoid valve stays closed, routing the pressurized swash plate, 11, is set at 15_ for low speed
charge pump oil to sump. The oil in the swash plate transmission operation.
29-16
2 3 4
6
15 5
17 7
10 11
A
A 12
14 16
9 8
13
“HIGH” OR RABBIT POSITION

20000745
14
1. Hydraulic suction filter 10. High pressure port
2. HST charge pump 11. High pressure port
3. Oil cooler 12. Cylinder passage
4. HST oil filter 13. Cylinder passage
5. Solenoid valve 14. Piston
6. Hi/Low switch 15. Steel pivot ball
7. Charge pressure oil passage 16. Swash plate
8. Hi/Low spool 17. Motor output shaft
9. Spool port
When the Hi/Low switch, 6, is moved to the high or The pressurized charge pump oil shifts the Hi/Low
rabbit position, electrical current is supplied to the spool against the spool return spring, as the spool
solenoid valve, 5. With current supplied, the solenoid shifts, high pressure passages, 10 and 11 are
valve, 5, moves to the open position, routing the connected to the cylinder passages, 12 and 13
pressurized charge pump oil to the Hi/Low spool, 8. allowing HST high pressure oil to be routed to the
swash plate pistons, 14. The pistons exert pressure
onto the backside of the swash plate, 16, and using
the steel pivot balls, 15 as fulcrum the swash plate
changes its angle of operation from15_ to 9_ for high
speed operation of motor output shaft, 17.
29-17
TROUBLESHOOTING
PROBLEM CHECK POSSIBLE CAUSE CORRECTION

Transmission fails to Input shaft rotation Input shaft failure Repair or replace as re-
operate, erratic or quired
abnormal noise when
operated Transmission fluid level Low oil supply Fill to proper level
Charge relief valve pres- Low charge pressure Check charge relief valve
sure
Clogged suction strainer Clean strainer
Oil viscosity high Replace oil
Charge pump defective Replace charge pump
Defective charge relief Replace relief valve

valve
High pressure relief valve Defective high pressure Replace valve

relief valve
Defective cylinder block Replace cylinder block
Tractor fails to stop at Pedal neutral position Linkage out of adjustment Adjust neutral position
neutral binding linkage
Neutral cannot be adjusted Replace trunnion shaft joint
Oil leakage Charge pump pressure Charge pressure too high, Replace charge pump relief
(above 12 kg/cm2 [170 psi]) valve
Pressure loss in filter ex-

cessive Replace filter
Return oil line restricted

Repair as required
Low power High pressure relief valve Valve pressure setting too Replace high pressure re-
low lief valves or replace port
block as required
Worn cylinder block Overhaul
Worn wear plates Overhaul

Oil overheating Cooler Dirty cooler fins Clean cooler fins
Incorrect oil Replace oil
Check valve in HST filter Binding valve or broken Clean or replace spring
base for proper operation spring
Binding charge pressure Clean or replace charge

relief valve pressure relief spring
29-18
PROBLEM CHECK POSSIBLE CAUSE CORRECTION

High range will not (F5) 7.5 amp fuse Blown fuse Replace 7.5 amp fuse
engage
Hi/Low switch Defective hi/low switch Replace hi/low switch
“Hi” range relay Defective relay Replace relay
Hi/Low solenoid Defective solenoid Replace solenoid
Solenoid valve Spool binding Clean and lubricate spool
Adapter block screen Plugged screen Clean screen
HST cylinder block spool Spool binding Clean and lubricate spool
Low charge pressure Stuck charge pressure Remove, clean or replace

relief valve charge relief valve
Defective charge pump Replace charge pump
Swash plate angling Stuck or oil blowing by Check piston fit in piston
pistons pistons bore
Low range will not Solenoid valve not de- Faulty electrical circuit Check electrical circuit to
engage energizing solenoid repair as needed
Swash plate angling Stuck piston in bore Check piston fit in bore
pistons repair as needed
29-19
CHARGE PUMP RELIEF VALVE

Test
Operate the tractor to warm the oil to 25° - 50 °C
(80° - 120 °F) before performing this hydraulic test.
1. Remove the oil pipe banjo bolt, 1, on the oil filter

base.
20000766
15
1. Banjo bolt
2. Install the modified banjo bolt, 1, for pressure

check. Modify banjo bolt locally. 1
3. Install a 0 - 20 bar (0 - 300 psi) gauge into the 2
banjo bolt.
4. Set the range selector lever in neutral.
5. Set the engine throttle at 2600 rpm. Read the
pressure gauge. Pressure reading should read
between 7.8 - 11.7 bar (114 - 170 psi).
If the charge pressure reading is low, check the

following:
20000775
• Restricted suction filter.
16
• Charge pump relief valve and spring (replace if 1. Banjo Bolt (for pressure check) SBA398480240
required). 2. Drill and tap - 1/8″ NPT
• The charge pump (repair if required).
30003060
17
29-20
PRESSURE TESTING AND ADJUSTMENTS

HIGH PRESSURE RELIEF VALVE
Operate the tractor to warm the hydraulic oil to 25° -
50 °C (80° -120 °F) before performing this hydraulic
test.
1. Remove the rubber floor mat and cover from the

center of the operator’s platform.
2. Remove the test port plug, 1, if testing reverse;
port, 2, if testing forward.
• Right side port -- Reverse
• Left side port -- Forward
1
2
30003067
18
3. Install HST Hi-pressure test fitting, 1, Tool No.
(NH #CNH299007, CIH #CAS2787) into the right
side test port. 1
30004745
19
29-21
4. Install a 0 - 450 bar (0 - 6500 psi) gauge, 2, to the
right side test fitting. (Reverse testing is 2
shown).
CAUTION
NOTE ORDER OF OPERATION:
1. Securely lock the parking brake.
2. Disengage the range gear and start the
engine.
1
2. Place the range lever in the high range 1
position.
30002891
5. Set the throttle speed to 2600 rpm.
20
6. Be sure the transmission foot pedals are in the
neutral position.
7. With the parking brake engaged, slowly move the
reverse foot pedal, 1, to obtain a reading on the 1
pressure gauge. Read the maximum pressure
on the gauge. Pressure should be 345 bar
(5000 psi).
IMPORTANT: Read pressure in the minimum of time
to prevent overheating and possible damage to the
transmission.
10997818
21
8. If necessary to replace either of the relief valves,
the operator’s platform has to be removed to gain 1
access to the relief valve ports, 1 (forward port
shown on left side of tractor -- reverse port on
right side of tractor).
30002884
22
29-22
9. To remove suspect relief valve, remove port plug,
1, with 10 mm allen wrench, O ring, 2, spring, 3, 5
and relief valve cartridge, 4. 1
NOTE: Relief valves are not adjustable, if a relief 2
valve is suspected as faulty, replace suspected valve 3
with new one. 4
10. Retest the new relief valve as previously

described. 4
3
2
1
20000774
23
1. Plug
2. O ring
3. Spring
4. High pressure relief valve
5. Port block
HI/LOW PRESSURE TEST

1. Remove pipe plug from rear of HI/LOW adapter
block.
2. Install adapter fitting (NH #FNH00011, CIH

#CAS2791) to adapter block port, 2. Fitting is:
1/8″ BSPT x 7/16-20 UNF.
20004742
24
3. Install a 0 - 200 bar (0 - 300 psi) gauge, 3, to
adapter fitting. 3 2
4. Start tractor, HI/LOW system when initially
started will default to “LOW” mode.
30003055
25
29-23
5. While the tractor is running and the valve is in the
“LOW/TURTLE” mode, zero pressure should be
present at test port.
30003069
26
6. While tractor is running switch HI/LOW switch to
the “HIGH/RABBIT” mode. When switch is in
“HIGH” pressure should be 7.8 - 11.7 bar (114 -
170 psi).
NOTE: The HI/LOW circuit is supplied oil by the HST
charge pump. The test results of the HST charge
pump pressure, that is measured at the HST filter
base and HI/LOW pressure test should have the
same readings. The HST charge pressure relief
valve regulates the pressure in both systems.
30003070
27
29-24
SEPARATING THE TRACTOR

DX35, DX40, AND DX45 W/HST
TRANSMISSION
Separating at the HST Housing/Engine
positive (+) battery cable, 2, from the battery. 2
1
transmission, differential, and the oil cooler into
a suitable container.
4. Remove the seat, and the seat track assembly
from the tractor deck.
10998231
28
5. Remove the control lever grips, 1, from the
control levers on both sides of the tractor. 1
6. Remove the left, 2, and the right, 3, control pods
from the fenders.
ROPS.
8. Disconnect and remove the control levers from
the tractor deck and the connecting linkage.
3
2
10997819/7820
29
29-25
9. If equipped, remove the remote, loader control
valve, 1, from the right fender, and the cup
holder/tool box, 2, from the left fender.
10. Remove the left and right fenders from the 1
tractor.
10998371/8229
30
11. Disconnect and remove the differential lock
pedal, 1.
10998223
31
29-26
12. If equipped, disconnect and remove the fulltime
2WD lever, 1.
1
13. Disconnect and remove the parking brake
handle, 2.
10998312
32
panels.
15. Remove the floor mat from the tractor deck.
10000864
33
16. Drive the roll pin, 1, (or spring clip if equipped)
from the HPL speed control shaft, 2, and remove
the control shaft from the HPL shaft, 3. 1
17. Remove the deck from the tractor. 3
2
20000903
34
29-27
retaining screws, 1. Remove the instrument 2
panel, 2, from the dash housing, 3. Disconnect 1
1
the wiring connector from the instrument panel.
19. Disconnect the throttle cable from the throttle
control lever.
20. Remove the dash housing from the firewall.
Disconnect the wiring connectors from the dash
switches.
3
21. Disconnect the two main wiring harness
connectors.
20045713
35
firewall, 2, and the HST housing, 3.
2
3
10000863
36
valve.
3 2
30997557
37
29-28
25. Remove the HST oil cooler tube, 1, and the HST
pressure tube, 2, from the tractor.
30996397
1
38
remove the starter from the tractor. 2
30997565 1
39
27. Remove the two FWD, driveshaft, front and rear,
retaining bolts, (one roll pin on standard FWD
axle), and remove the driveshaft from the tractor.
1 2
30996382
40
29-29
28. Use a floor jack, 1, to raise the front of the tractor
and place wood blocks, 2, between the axle, 3,
and the frame, 4. Lower the jack.
1
4 2
3
10000866
41
29. Remove the cotter pin, 1, and the castle nut, 2,
from the support bar, 3, at the rear mounting
bracket, 4.
30. Use a brass drift and a hammer to drive the
support bar, 3, stud out of the mounting
bracket, 4.
filter is necessary on the DX35 tractor to gain access
4 1
3
31. Drain the engine oil into a suitable container and
remove the oil filter. 10000902
2
42
2
10000865 1
43
29-30
and 3, on the engine. 1
10000867
44
2
1
10000868
45
36. Roll a floor jack under the tractor from the rear of
the tractor, and place under the HST housing.
37. Remove the buckle-up bolts that secure the
engine to the HST housing.
engine from the HST housing.
10000869
46
29-31
10000870
47
Separating the HST Housing at the Gearbox
2
1. Place a jack stand, 1, under the gearbox, 2, to
support the drive train.
1
10000909
48
29-32
2. Remove the HST pedals and linkage, from the
right side of the gearbox, and the HST housing.
20000910
49
NOTE: Remove and discard O rings. Replace with
new O rings at assembly.
1
3. Remove the hydraulic tube, 1, the hydraulic
control valve, 2, and the valve body, 3, from the
gearbox and the HST housing.
10000911
50
29-33
4. Remove the hydraulic tube, 1, from the HST
housing, 2. Remove the retaining bolt, 3, from the
diverter valve bracket, 4.
3
4
2
10000912
51
5. Loosen and remove the buckle-up bolts and
buckle-up nuts. Separate and remove the HST 2 1
housing, 1, from the gearbox, 2.
10000913
52
Attaching the HST Housing to the Gearbox
2 1
1. Position the HST housing, 1, onto the gearbox,
2, and secure with the buckle-up bolts, and
buckle-up nuts. Tighten the bolts and the nuts to
81 N⋅m (60 ft. lbs.).
10000913
53
29-34
NOTE: Use new O rings on hydraulic tubes during
assembly.
2. Install and connect the hydraulic tube, 1, to the

HST housing, 2. Attach the diverter valve 1
bracket, 4, to the HST housing, 2, and secure
with the retaining bolt, 3.
3
4
2
10000912
54
3. Install the valve body, 3, the hydraulic control
valve, 2, and the hydraulic tube, 1, onto the HST
housing and the gearbox.
1
10000911
55
29-35
4. Install the HST pedals and linkage, on the right
side of the gearbox, and the HST housing.
20000910
56
29-36
Attaching the HST to the Engine
WARNING
WARNING: Do not use the buckle-up bolts to
draw the HST together with the engine. Severe
damage to the drive train may result.

the engine. Align the splines on the HST input
shaft with the coupler on the engine flywheel.
the coupler. The floor jack or the hoist may need
to be raised or lowered to make alignment
possible.
2. Connect the HST housing to the engine and
install the buckle-up bolts and nuts. Tighten the
buckle-up bolts and nuts in a criss-cross pattern.
Torque the M10 bolts and nuts to 43.4 - 55.6 N⋅m
(32 - 41 ft. lbs.). Torque the two M12 bolts to 81 N⋅m
(60 ft. lbs.). 10000869
57
the tractor.
2
1
10000868
58
4. Connect the fuel supply line, 1, to the fuel
shutoff/filter, 3, and connect the fuel tank vent
line, 2, to the tee fitting.
10000865 1 3
59
29-37
5. Attach the firewall support, 1, to the HST
housing, 3, and the firewall, 2. Secure with the
retaining bolts. 2
3
10000863
60
6. Install the FWD driveshaft, 2, and secure with the
two retaining bolts, 1, (one roll pin on standard
FWD axle).
1 2
30996382
61
7. Install the support bar stud, 3, into the mount, 4,
and secure with the castle nut, 2. Torque the
castle nut to 135.6 - 169.5 N⋅m (100 - 125 ft. lbs.).
Install a new cotter pin, 1, through the castle nut,
2, and the support bar stud, 3.
4 1
3
10000902
2
62
29-38
8. Place a floor jack, 1, under the front of the tractor,
and raise the tractor. Remove the wood blocks,
2, from between the front axle, 3, and the
frame, 4.
1
4 2
3
10000866
63
with the retaining nuts. Connect the wires, 1, to 2
the starter, 2.
30997565 1
64
10. Install the HST oil cooler tube, 1, and the HST
pressure tube, 2, onto the tractor.
30996397
1
65
29-39
hydraulic pump, 2.
13. Connect the two main wiring harness connec-
tors.
14. Install the tractor deck onto the tractor.
3 2
30997557
66
15. Install and connect the differential lock pedal, 1.
NOTE: For ease of control lever assembly, raise the
tractor on a floor jack and remove the rear wheels.
This is not required but will ease assembly.
10998223
67
16. Install and connect the full time 2WD lever, 1
17. Install and connect the parking brake lever, 2. 1
10998312
68
29-40
18. Install the HPL speed control shaft, 2, onto the
HPL shaft, 3.
1
19. Install and connect the control levers on the left
and right side of the tractor deck. 3
20. Install the left and right fenders on the tractor. 2
20000903
69
29-41
21. Install the left, 2, and right, 3, control pods on the
fenders. Install the control lever grips, 1, on the 1
control levers.
22. Install the floor mat onto the tractor deck.
23. Install the seat and the seat track on the tractor.
ROPS.
3
2
10997819/7820
70
25. Install the cup holder/tool box, 2, on the left
fender, if equipped.
26. Install the remote, loader control valve, 1, on the
right fender, if equipped. Connect the hydraulic 1
tubes.
28. Connect the wiring plugs to the dash housing
switches.
10998371/8229
71
29-42
instrument panel. Install the instrument panel, 2,
into the dash housing, 3, and secure with two
screws, 1.
30. Install the hood on the tractor.
10998223
72
panels.
32. If removed, install the left and right rear wheels.
33. Fill the hydraulic reservoir with Hy-Tran Ultra
hydraulic fluid, to the proper level.
NOTE: The following step is required on the DX35 1
tractor.
2
recommended oil to the proper level. 10000864
73
1
10998312
74
29-43
Op. 29 202
HYDROSTATIC TRANSMISSION
Precautions Before Disassembly

• Thoroughly clean the HST unit and plug all
openings to prevent dirt entry.
• Keep the work area clean at all times and use
care to not contaminate the internal parts.
• Handle the parts carefully so as not to damage
parts during repair.
Disassembly
1. Drain the transmission fluid into a suitable clean
container.
2. Separate the tractor between the engine and
clutch housing. See “Separating the Tractor”.
3. Remove the clutch housing.
4. Remove the two hex nuts and hex head cap
screws, 1, and remove the HST from the 1 1
transmission case.
1
30996513
75
CHARGE PUMP
7
Removal
1. Remove the socket head bolt, 1. 6
3
2. Remove the charge pump case, 2, and O ring, 3, 5
from the housing, 4. 2
3. Remove the inner and outer rotor assembly, 5,
from the input shaft, 6.
9
NOTE: Identify the position of the inner and outer
rotor so as to re-assembly in their original position. 10 4
1 8
4. Remove the key, 7, from the input shaft, 6. 20000746
5. Remove the plate, 8, washer, 9, and O ring, 10, 76

from the housing.
29-44
Op. 29 130
1
PORT BLOCK
3
Removal
2
1. Remove the 11 socket head bolts, 1 and remove
the port block, 2, from the housing, 3.
20000747
77
2. Remove the charge pressure relief valve, 1, and
spring, 2. 1
NOTE: Take care not to drop the valve plates (3 2
and 4).
3
3. Remove pump valve plate, 3 and motor valve
plate, 4, from the port block, 5.
5
4
20000748
78
IMPORTANT: Take note of the orientation of the
feathering notches, (A), on the valve plates (3 and 4).
3 A
pump
A
A
4
40044347
motor
A 40044348
79
29-45
CYLINDER BLOCK ASSEMBLY

1
Removal
1. Remove the pump cylinder block assembly, 1,
from the housing.
2. Remove the motor cylinder block assembly, 2,
from the housing.
2
20000749
80
MOTOR SWASH PLATE
4
Removal
1. Remove the motor swash plate, 1, from the
housing.
2. Remove the pistons, 2, spring, 3 and steel
balls, 4. 1
2
3
20000750
81
29-46
INPUT AND OUTPUT SHAFT

1
Removal
1. Remove the thrust plate, 1, from the housing.
2. Using a soft jaw hammer, drive out the input
shaft, 2. 2
3. Remove the snap ring, 3, and output shaft, 4, with 4
bearing, 5, from the housing. 3
5
20000751
82
PUMP SWASH PLATE 7
Removal 4 1
5
1. Scribe reference marks on the swash plate 6
covers, 2 and 3, and remove the covers from the
housing.
2. Using a soft mallet, gently tap the axial end of the 6
swash plate and remove the opposite side cover. 5
2 7
3. Gently tap the exposed trunnion end and remove
the remaining cover.
4. Remove the variable swash plate, 1, from the 3
housing. 20000752
83
1. Pump swash plate
2. Right-hand cover
3. Left-hand cover
4. Oil seal
5. O ring
6. Bushing
7. Screw
29-47
Op. 29 130
1
2 3
PORT BLOCK
Removal 4
5 2
1. Remove the plug, 1, O rings, 2, spring, 3, and 6 4
high pressure relief valve and check valve, 4, as 3
an assembly.
2. Remove the plugs, 4 and 5, O rings, 6, spool, 7, 1
and spring, 8, for the two speed motor.
8
7
6 4
20000753
84
Inspection
Inspect the hydrostatic components for the following
conditions:
• Excessive wear or scored pistons and cylinder

bores in the pump and motor block assemblies.
• Excessive wear or scored cylinder block and
valve port plate mating surfaces.
• Excessive wear or scored charge pump rotor
faces and lobes.
• Excessive wear or scored charge pump body
and wear plate surfaces.
• Check the ball bearings for excessive wear and
looseness or uneven rotation when rotated by
hand.
• Inspect the variable swash plate bushings for
excessive wear or scoring. Replace the cover
and bushing as an assembly if required.
NOTE: BEFORE ASSEMBLY, BE SURE:

• ALL COMPONENTS ARE THOROUGHLY
CLEANED AND WELL LUBRICATED WITH
HY-TRAN ULTRA.
• REPLACE O RINGS, OIL SEALS AND GAS-
KETS WHEN REASSEMBLING.
• APPLY PETROLEUM JELLY TO O RINGS AND
OIL SEAL LIPS.
29-48
PISTON
1 2
Inspection
• Replace the piston assembly if the play at the
caulked areas, 3, of the piston, 2, and shoe, 1,
exceeds the service limit.
Standard Assembly
Valve Service Limit
3
0.03 mm (0.001 in.) 0.1 mm (0.004 in.)
PLAY
20000754
85
• Replace the piston assembly if the shoe
thickness, 3, is below the service limit. 3
Standard Assembly
Valve Service Limit
3.0 mm (0.118 in.) 2.9 mm (0.114 in.)
20000755
86
• Replace the piston assembly if the clearance, 3,
between the piston, 1, and cylinder block, 2, 3 2
exceeds the service limit. 1
Standard Assembly
Valve Service Limit
0.02 mm (0.0007 in.) 0.03 mm (0.001 in.)
20000756
87
29-49
CHARGE PUMP
Inspection 3
1
• Measure the side clearance, 3, of the trochoid
rotor and replace if the service limit is exceeded.
Standard Assembly
Valve Service Limit
0.02 - 0.03 mm 0.035 mm
(0.0007 - 0.001 in.) (0.0014 in.)
2
20000757
88
1. Trochoid rotor assembly
2. Charge pump case
3. Clearance
SWASH PLATE 7
Assembly 4 1
5
1. Install the pump swash plate, 1, into the housing. 6
2. Align the reference marks and install the covers,
2 and 3, into the housing.
3. Install the screws, 7, and tighten to 6.1 - 7.3 N⋅m 6
5
(4.50 - 5.38 ft. lbs.). 2 7
3
20000752
89
1. Pump swash plate
2. Right-hand cover
3. Left-hand cover
4. Oil seal
5. O ring
6. Bushing
7. Screw
4. Take care that the cover notch, 1, is toward the

port block mounting screw when installing the
covers.
20000758
90
29-50
PUMP SHAFT (INPUT SHAFT)

4
Assembly
1. If removed, install the bearing, 1, and snap ring,
2, to the pump shaft, 3. 1
2. Install the pump shaft into the housing, 4, from
the front.
2
3
20000759
91
CHARGE PUMP
Assembly 7
1. Install the washer, 1, and O ring, 2, to the 5
housing. 9 4
2. Install the pin, 3, and plate, 4, to the housing. 6
3. Install the key, 5, and trochoid rotor assembly, 6, 8
onto the pump shaft, 7.
4. Install the charge pump case, 8, and O ring, 9, 3
with socket head bolts, 10, and tighten to 17.0 - 1
18.4 N⋅m (12.5 - 13.6 ft. lbs.). 10 2
20000760
92
Op. 29 218
2
CYLINDER BLOCK
Assembly for Pump
1. Install the thrust plate, 1, into the swash plate 3
while aligning pin, 2, and pin hole.
1
2. Install the cylinder block assembly, 3.
20000761
93
29-51
NOTE: Take care not to lose the three pins, 2, from
the pump cylinder block, 1. Ensure that they are
installed into the piston block. 1
2
94
MOTOR SHAFT
4
Assembly
1. Install the ball bearing, 1, and snap ring, 2, onto
the motor shaft, 3.
2. Install the motor shaft, 3, into the housing, 4, and
secure by the snap ring, 5. 3
5
2 1
20000762
95
Op. 29 218
4
CYLINDER BLOCK 3
Assembly for Motor
1. Install the spring, 1, and pistons, 2, into the
housing.
5
2. Install the steel balls, 3, into the housing.
3. Install the motor swash plate, 4, into the housing.
4. Install the cylinder block assembly, 5, into the 2
housing.
1
20000763
96
29-52
Op. 29 130
4 10
PORT BLOCK 3
Assembly 1
7
1. Install the check valve and high pressure relief
valve, 1, as a set into the port block, 2.
1
2. Install the spring, 3, O rings, 10, and plug, 4, and 3
tighten to 63.1 - 64.3 N⋅m (46.6 - 47.5 ft. lbs.). 10
3. Install the spool, 5, spring, 6, O rings, 9, and
plugs, 7, and adapter fitting, 8, and tighten to 9
51.0 N⋅m (69 ft. lbs.). 6 5
NOTE: Use care at the position of plugs, 7 and 8, and
direction of the springs, 3, and spool, 5.
4
NOTE:Spool should be a sliding fit with no binding in 2
the bore. Polish if needed. Lubricate with hydraulic oil 9
when installing. 20000764
8
97
1. Check and high pressure
relief valve assembly
2. Port block
3. Spring
4. Plug
5. Spool
6. Spring
7. Plug
8. Adapter fitting
9. O ring
10. O ring
29-53
11
4
9 10
12 5 3
2
13
8
pump motor A
A
20000765 A 40044348
A 40044347
98
1. Pump valve plate 6. Pin 10. Spring
2. Motor valve plate 7. Housing 11. Socket head bolt
3. Port block 8. O ring 12. Input shaft
4. Charge pressure relief valve 9. Metal gasket 13. Output shaft
5. O ring
Installation 6. Install the metal gasket, 9, to the housing, 7.

1. Install the valve plates, 1 and 2, to the port block 7. Lubricate the contact surface of the cylinder
assembly, 3. blocks.
NOTE: Ensure feathering notches, A, are facing 8. Install the spring, 10, for charge pressure relief
outward from the port block. valve to the housing, 7. Use petroleum jelly to
install spring in position.
2. Install the charge pressure relief valve, 4, to the 9. Install the port block assembly, 3, to the housing,
port block. 7, and tighten the socket bolts, 11, to 69.9 - 71.3
3. Install the O rings, 5, to the port block. N⋅m (51.5 - 52.5 ft. lbs.).
4. If removed, install the pins, 6, to the housing, 7. 10. Using pliers to help grip shafts, input shaft, 12,
5. Install the O rings, 8, to the housing, 7. and output shaft, 13, should rotate. If not, inspect.
29-54
HYDROSTATIC TRANSMISSION
1 1
Assembly
1. Install the two hex nuts and hex cap head screws,
1, and install the HST to the transmission case.
2. Install the clutch housing.
3. Reassemble the tractor between the engine and
clutch housing.
1
30996513
99
Op. 29 204
6
CHECK VALVE
Description of Operation
A check valve in the pipe circuit protects the cooler
from excess pressure due to high oil viscosity or a
restriction in the cooler circuit.
NOTE: Check valve opens when there is 17.5 psi 5

pressure differential between the inlet and outlet of
the filter base.
NOTE: When the check valve opens, oil bypasses

the oil cooler but still circulates through the filter. 100
Oil flow directional arrows shown in figure. 1. Banjo bolt
2. Spring
3. Ball
4. Cooler return manifold tube
5. Cooler supply tube
6. Transmission supply tube
Disassembly
1. Remove the front banjo bolt, 1 (from cooler pipe
tube).
2. Remove the spring, 2, and steel ball, 3, from the
filter holder, 4.
Inspection
1. Inspect the spring and ball for excess wear or
damage. Replace faulty components if required.
2. Inspect the ball seat in the filter holder. Replace 4
the filter holder if required.
3
2
Assembly
Assemble the check valve components as shown in 1
the prior figure.
20000766
101
29-55
DESCRIPTION AND OPERATION -- GEARBOX

Op. 29 300
GEARBOX 2
The hydrostatic transmission unit used on the
tractors has two output shafts, 2 and 3, to the
transmission gearbox. One output shaft, 3, provides
power to the transmission gearbox and drives the 3
rear axle drive pinion. The other output shaft, 2,
provides power to the transmission gearbox for PTO
drive.
20000767
102
1. Input Shaft
2. Output Shaft for PTO
3. Output Shaft for rear axle drive pinion
29-56
GEARBOX IDENTIFICATION
The hydrostatic transmission gearbox is a two speed
non-syncromesh type gearbox, that transfers power
from the output shaft of the hydrostatic transmission
to either the rear axle pinion gear or front wheel drive
drop box gear.
4
5 6
1
2 8 9
7
3 4
2
20003063
103
1. Input shaft 6. 19-tooth fixed gear
2. 20-tooth lower counter shaft gear 7. 29-tooth high range gear
3. 21-tooth mid counter shaft gear 8. Range gear sliding coupler
4. 26-tooth upper shaft front gear 9. 41-tooth low range gear
5. 31-tooth fixed gear
29-57
OVERHAUL -- GEARBOX
GEARBOX
Removal 1
1. Drain the transmission fluid into a suitable
container.
3
2. Separate the tractor between the bell housing 4
and the engine. See “Separating the Tractor”.
3. Remove the hydrostatic transmission. See
“Hydrostatic Transmission Disassembly” dis-
cussed earlier in this section. 2
4. Remove the PTO solenoid valve, 1, and
hydraulic line, 2. 10998443
5. Remove the hex head cap screws, 3, and 104

remove the transmission cover and gasket, 4.
6. Remove pin, 1, spring, 2 and ball, 3, from the
case, 4. 1
2
4 3
20000768
105
7. Remove the transmission to rear axle buckle-up
bolts, 1, and separate the transmission from the
rear axle.
NOTE: Three of the buckle-up bolts, 1, are located in 1
the transmission case under the top cover.
10998444
106
29-58
Disassembly
1. Remove and discard the PTO drive shaft seal, 1.
1
10998445
107
2. Remove the snap ring, 1, and remove the PTO
drive shaft, 2, with bearing from the front of the
casing.
1
10998446
108
3. Remove the snap ring, 1, securing the counter
shaft at the rear of the casing.
10998447
109
29-59
4. Remove the counter shaft from the rear of the
casing removing the front bearing, 1, fixed gear
(19T), 2, collar, 3, and high fixed gear (31T), 4, 4 3 2
from the shaft. The low fixed gear (26T), 5, and 1
rear bearing, 6, will remain on the shaft. 6 5
10998448
110
5. Remove and discard the counter shaft oil seal, 1,
from the front of the case.
10998445
111
6. Remove snap ring, 1.
7. Remove the counter shaft, 2, through the front of
the case with front bearing, 3.
5
8. Remove the fixed gear (21T), 4, and rear 4
bearing, 5, from the case. 2
3
1
20000769
112
29-60
9. Drive the spring pin, 1, through the shift rod, 2,
and fork, 3.
3
2 1
10998451
113
10. Remove the shift rod, 1, from the rear of the case.
11. Remove the shift fork, 2. 1
10998452
114
12. Remove the snap ring, 1, securing the main shaft
assembly.
10998447
115
29-61
13. Withdraw the main shaft, 2, with rear bearing, 3,
through the rear of the case. 5
6
14. Remove the main coupling, 1, low counter gear 9
(41T), 5, hub, 9, slide gear, 6, high counter gear 8
(29T), 4, main coupling, 8, and front bearing, 7, 2
7
from the case. 3
1
4
20000770
116
15. Remove and discard the drive shaft oil seal, 1,
10998445
117
16. Remove the snap ring, 1.
10998454
118
29-62
17. Remove the drive shaft, 1, with front bearing, 2,
18. Remove the fixed gear (20T), 3, and rear
bearing, 4, from the case. 5
4
2
3
1
20000769
119
Inspection
1. Wash all components with a suitable cleaning
2. Inspect all bearings for excess wear, score
marks, discoloration from overheating, or other
damage. Rotate the bearings by hand and check
for roughness while slowly rotating the inner and
outer races.
3. Lubricate all bearings with clean hydraulic fluid,
Hy-Tran Ultra or equivalent, before installation.
4. Inspect the transmission case for, pitting, cracks,
worn bearing bores, or other damage.
5. Check the detent springs for wear, chip, or weak
spring tension.
6. Inspect the detent balls for excess wear or
damage.
7. Inspect the shift rail detent grooves for, pitting,
excess wear, or other damage.
8. Inspect all gears for excess wear, chipped teeth,
or other damage. Check the gear backlash by
inserting the mating assemblies into the casing
and using a feeler gauge. Gear backlash should
be between 0.4 - 0.6 mm (0.002″ - 0.006″) with
a maximum wear limit of 0.6 mm (0.236″).
9. Inspect the shift forks for excess wear, bending,
or other damage.
29-63
Assembly
1. Install the drive shaft rear bearing, 4, in the bore
of the casing and install the fixed gear (20T), 3,
in position.
2. Insert the drive shaft, 1, with front bearing, 2,
through the front of the case through the fixed
gear until it bottoms out in the rear bearing.
4
3
1
20000769
2
120
3. Install snap ring, 1, to secure the drive shaft
assembly in position.
10998454
121
4. Install the new drive shaft oil seal, 1.
10998445
122
29-64
5. Install the main shaft front bearing, 7, in its bore
in the casing. 5
6
6. Assemble the main coupling, 8, high counter 9
gear (29T), 4, slide gear, 6, hub, 9, low counter 8
gear (41T), 5, and main coupling, 1, and place in 2
7
position in the case. 3
7. Install the main shaft with rear bearing, 1, through 1
the rear of the case through the gear assembly
until it bottoms out in the front bearing. 4
20000770
123
8. Install the shift fork, 3, in position and insert the
shift rod, 2, through the fork and case. Secure in
position with spring pin, 1. 3
2 1
10998451
124
9. Install the counter shaft rear bearing, 5, in its bore
in the case.
10. Install the fixed gear (21T), 4, in position in the
case, then install the counter shaft, 2, with front 5
4
bearing, 3, through the front of the case through 2
the fixed gear until it bottoms out in the rear 3
bearing. 1
11. Install the snap ring, 1, to secure the counter
shaft assembly.
20000769
125
29-65
12. Install the new counter shaft oil seal, 1.
10998445
126
13. Install the front bearing, 1, in its bore in the case.
14. Install the high fixed gear, (31T), 4, collar, 3, fixed
4 3 2
gear (26T), 2, in position in the case. 1
15. Install the counter shaft with low fixed gear (19T), 6 5
5, and rear bearing, 6, from the rear of the case
through the gear assembly until it bottoms out in
the front bearing.
10998448
127
16. Install the snap ring, 1, in its groove in the rear of
the case.
10998447
128
29-66
17. Install the PTO drive shaft, 2, with bearing
through the front of the counter shaft and secure
with snap ring, 1.
1
10998446
129
18. Install the new PTO drive shaft seal, 1.
1
10998445
130
29-67
Installation
1. Apply a light coat of Loctite sealer, gasket
eliminator #518, to the mating surfaces of the
rear axle and transmission housing. Align the 1
transmission housing with the rear axle and
install the buckle-up bolts. Tighten to 81 N⋅m (60
ft. lbs.).
NOTE: Three of the buckle-up bolts, 1, are located in
the transmission case under the top cover.
10998444
131
2. Install the detent ball, 3, spring, 2, and pin, 1, into
the case, 4. 1
2
4 3
20000768
132
3. Using a new gasket, install the transmission
cover, 4. Secure the cover with hex head cap
screws, 3. 1
4. Install the PTO solenoid valve, 1, and hydraulic
line, 2. 3
4
5. Install the hydrostatic transmission. See “Hydro-
static Transmission Assembly” discussed earlier
in this section.
10998443
133
29-68
Op. 29 214
HI/LO SOLENOID VALVE

The solenoid valve controls the motor swash plate
angle by controlling the flow of charge pump
pressurized oil. When the solenoid valve is
deactivated, by the Hi/LO switch being in the “Turtle”
position, no charge pump oil is allowed to flow
through the valve to the angling pistons. In the
(LOW/TURTLE) mode the swash plate angle is at
15_.
1 2 3
Port Identification
1. Pressurized inlet
2. Pressurized outlet to pistons
3. Return to sump
20004747
134
29-69
When the solenoid is activated, by placing the HI/LO
switch in the “Rabbit” position, the spool is shifted
allowing charge pump pressurized oil to flow to the
angling pistons that are located under the motor
swash plate. When the pistons are pressurized, the
motor swash plate angle moves from 15_ to 9_ for
(HI/RABBIT) mode operation.
1 2 3
Port Identification
1. Pressurized inlet
2. Pressurized outlet to pistons
3. Return to sump
20004746
135
The solenoid valve assembly, 1, is located on the left
side of the transmission case.
30002884 1
136
29-70
Removal
1. Disconnect wires, 1.
2. Using a 5 mm allen wrench, remove the four
socket head mounting bolts, 2.
1
2
30002884
137
3. When removing the valve assembly, be careful
not to displace the three O rings, 3, that are
located between the solenoid valve body and the
adapter block.
30002887
138
Disassembly
1. Remove solenoid retaining nut, 1, spacer, 2,
solenoid cover, 3, and solenoid, 4, from valve
stem.
1
3
4 2
30002888
139
29-71
2. Remove valve stem, 5, O ring, 6, plunger, 7,
spool, 8, and spring, 9, from valve body.
7
8
9
5
30002889
140
Inspection
1. Check solenoid, 1, for damaged wires.
2. Plunger, 2, should slide freely in and out of valve 2
stem, 3. 4
5
3. Spool, 4, should be a smooth sliding fit inside of
valve body bore, if spool is binding check for
contamination in bore or for rough spots on
spool. Spool can be polished with fine emery
paper if needed.
4. Check spring, 5, for any damage or distortion.
3 1
30002889
141
Testing
1
1. Assemble nut, 1, spacer, 2 solenoid cover, 3, 2
3
solenoid, 4, valve stem, 5, and plunger, 6. 4
5
6
30003065
142
29-72
2. Apply 12 volt power source to the solenoid
leads, 1. 1
3. When 12 volts are supplied to solenoid leads,
plunger, 2, should protrude from valve stem.
Valve stem should become magnetized when
solenoid is supplied with electrical current. 2
30003061
143
4. Check ohm reading across leads of solenoid.
Reading should be 7.5 to 10.5 ohms.
5. If plunger does not protrude when voltage is
applied or resistance reading is not within
specification, replace solenoid.
1
30000740
144
Assembly
NOTE: Clean and lubricate spool before installing
into valve body. 3
2
1. Install spring, 1, spool, 2, plunger, 3, valve stem, 1
4, with O ring, 5, solenoid, 6, cover, 7, spacer, 8
and nut, 9.
5
8
7 9
30002889
4 6
145
29-73
2. Install the three O rings, 1 onto backside of valve
body.
30002887
146
3. Install valve body onto adapter block with the four
socket head bolts. Torque to 5.6 N⋅m (50 in. lbs.).
30002884 1
147
ADAPTER BLOCK
Removal
NOTE: Solenoid valve must be removed before
adapter block can be removed from transmission
case.
1. Remove metal line, 1, and hose, 2, from adapter

block.
30003066 1 2
148
29-74
2. Using a 6 mm allen wrench remove the two
socket head bolts mounting bolts, 1.
1
30002885
149
3. Pull adapter block assembly away from internal
hydrostatic transmission.
30002886
150
Disassembly
2 4
1. Remove adapter fitting, 1, and O rings, 2, from
block. 3
2. Remove O ring, 3, and screen, 4, from block port.
1
30002890
151
29-75
Inspection
1
1. Inspect all O rings, 1, for damage and replace as
2
needed.
2. Clean screen,, 2, with solvent and compressed
air.
30002890
152
Assembly
5 4
1. Install screen, 1, and O ring, 2 into bore of block.
NOTE: O ring, 2, is sandwiched between screen, 1,
and adapter fitting, 3.
2. Install adapter fitting, 3, with O rings, 4, and, 5

into block.
2
30002890
3 1
153
3. Install adapter block assembly into Hydrostatic
transmission port, secure with two socket head
bolts, 6, tighten bolts to 27 N⋅m (20 ft. lbs.).
30002885 6
154
29-76
4. Install hose, 7, and metal line, 8.
8 7
30003066
155
CRUISE CONTROL
An electronic cruise control system is standard
equipment on models DX35, DX40 and DX45. The
cruise control system utilizes an electromagnet, to
lock the hydrostatic transmission linkage in any
position and maintain a constant selected forward or
reverse speed.
The cruise control is activated by a three--position
momentary rocker switch, 1, that is located on the 1
right--hand side pod. When cruise control system is
activated the tractor symbol on the switch will be
illuminated green, indicating the system is “ON”.
After starting the tractor and reaching the desired

operating speed, engage the cruise control by:
• Place the ignition switch in the “ACC/RUN”

position.
• Having the parking brake or both brake pedals
are in the released position. 10998318
• Depressing the top side of the cruise control
switch. 156
29-77
This activates the electromagnet, 1, which holds the
hydrostatic pedal in place. 1
The cruise control can be disengaged by:
• Depressing both brake pedals.

(Depressing both pedals activates cruise release
brake switch).
• Placing the cruise control switch in the “OFF”
position.
When either one of the above actions take place, the

electric current to the magnet is interrupted, and the 30002223
hydrostatic pedal returns to neutral.
157
NOTE: The cruise control can be overridden by
pushing on the hydrostatic pedals with enough force
to force the linkage past the electromagnet. If the
cruise is over ridden, once the force on the pedal is
removed the cruise will be set at the new speed
position.
NOTE: When the ignition key is turned to the “OFF”

position, the cruise control will default to the “OFF”
position.
ELECTROMAGNET AIR GAP

Adjustment 2
With the tractor turned off and the cruise control
deactivated, loosen bolts, 1, on magnet mounting
plate. Move mounting plate inboard or outboard to
obtain an air gap, 4, of 0.5 – 1.5 mm (0.020 – 0.060
in.) between magnet, 2, and pivot plate, 3. Retighten
mounting bolts, 1.
1
NOTE: Troubleshooting cruise control system is
covered in Section 55, Electrical. 4
3
20003060
158
29-78
Chapter 2 -- Adjustment
CONTENT

HST Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HST Cruise Control Magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
29 200 HST Foot Control Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HST Pedals Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
29-1
HST PEDALS
Stop Adjustment
1. Adjust the forward HST pedal stop, 1, to 22.5 mm
(.9 in.), and the reverse HST pedal stop, 2, to 28 mm 2
(1 in.). 1
20020300
1
2. Loosen the two bolts, 1, and adjust the forward
HST pedal to be aligned with the reverse HST
pedal.
1
20000916
29-2
HST CRUISE CONTROL MAGNET

Adjustment
1. Loosen the two bolts, 1, and move the bracket,
2, to obtain 1 mm (0.039 in.) clearance between
the plate, 3, and the magnet, 4.
2. Remove the jack stand from under the gearbox,
and place under the HST housing to support the
drive line during attachment of the HST housing
to the engine.
2
1
Adjust Bracket
to Obtain
1 ± 0.5 mm (0.040 in.)
Between Plate
20000917
and Magnet
3
29-3
Op. 29 200
HST FOOT CONTROL PEDALS

Neutral Adjustment
When The HST foot control pedals are in the neutral
position, the rear wheels should not creep. To check
and adjust neutral pedal position:
Standard FWD Axle
1. Disengage the FWD and jack the rear wheels off

the ground and support rear axles with jack
stands.
2. With axle(s) off the ground, start the tractor, place
the transmission range selector in the “HI” range
position.
3. Set engine to full RPM.
4. DO NOT depress either foot pedal and check for
creep in the rear wheels.
5. Full stroke both the forward and reverse pedals,
allow pedals to return to neutral and check for
creep.
10997818
4
If creep exists in either direction, adjust s follows:
6. Loosen capscrew, 1, and adjust large hex head 2

eccentric, 2, until creep stops.
7. Retighten capscrew, 1. Be sure eccentric, 2,
stays in place while tightening capscrew.
NOTE: For optimum adjustment, turn eccentric, 2,
clockwise until wheels begin to creep (mark 1
position), then turn eccentric counterclockwise until
wheels begin to creep in the opposite direction,
(mark position). Eccentric adjustment should be
made at mid position between the two marks. Pedals
10000742
should be level.
5
8. Pull back engine speed to idle and stop engine.
9. Remove jack stands that support axle(s) and
lower tractor to the ground.
29-4
HST PEDALS RETURN SPRING

Adjustment 1
Adjust the pedal return spring as follows: 2
1. Tractor turned off, and HST pedals in neutral 3
position.
2. Loosen jam nut, 1.
3. Turn nut, 2, clockwise for more spring tension
and counter clockwise for less tension.
4. Adjust nut until spring measurement, 3, (hook to
hook) is 120 mm ± 2.0 mm (4-11/16 in ± 5/64 in). 30003068
5. Tighten jam nut, 1. 6
29-5
29-6
SECTION 31 -- POWER TAKE-OFF (PTO) SYSTEMS -- CHAPTER 1
Chapter 1 -- Power Take-Off (PTO) Systems
CONTENT

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PTO Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
31 110 Rear PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power Flow Diagram for the 12 x 12 Synchronized Shuttle Shift Transmission . . . . . 7
Power Flow Diagram for the Hydrostatic Transmission (HST) . . . . . . . . . . . . . . . . . . 8
31 120 Power Flow Diagram for Tractors Equipped with a Mid PTO Kit . . . . . . . . . . . . . . . . 9
31 104 Hydraulic Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PTO Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Test Procedure (Below Serial Number -- See Chart) . . . . . . . . . . . . . . . . . . . . . . . . 14
Test Procedure (Serial Number and Above -- See Chart) . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
31 104 82 PTO System Diverter Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
31 104 82 PTO Clutch Control Valve (BSN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Clutch Control Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
31 104 82 PTO Clutch Control Valve (ASN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
31-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
31 114 62 PTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
31 114 68 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
31 114 62 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
31 114 42 Power Take Off System System for 12 x 12 Synchronized Shuttle Shift Transmission . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
PTO Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
31 114 46 Countershaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
31 114 00 PTO System for Hydrostatic Transmission (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
31 114 42 PTO Input Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
31 114 42 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
31 114 19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
31 120 00 Mid PTO Countershaft and Drop Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
31-2
SPECIFICATIONS
PTO HYDRAULIC SYSTEM

Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 lpm (0.8 gpm)
Relief Valve Pressure Setting
D35, DX35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 bar (200 psi)
D40, DX40, D45, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 bar (260 psi)
PTO CLUTCH
Clutch Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet
Clutch Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Asbestos Free
Clutch Disc Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 discs
Minimum Clutch Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.80 mm (0.71″)
Clutch Disc Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm (3.937″)
Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm - 2.5 mm (0.059″ - 0.098″)
Minimum Brake Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.35 mm (0.93″)
Brake Disc Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118.7 mm (4.675″)
31-3

4T, 4.8 2.8 - 4.0 3.8 - 5.4
M5 7T, 8T, 8.8 0.70 4.9 - 6.9 6.9 - 9.3 ----------- ------------ ------------
10T, 10.9, 11T 6.7 - 9.4 9.0 - 12.7
4T, 4.8 3.6 - 5.1 4.9 - 6.9
M6 7T, 8T, 8.8 1.0 6.1 - 8.3 8.3 - 11.3 ----------- ------------ ------------
10T, 10.9, 11T 8.7 - 11.6 11.8 - 15.7
4T, 4.8 9.4 - 12.3 12.7 - 16.7 11.2 - 14.8 15.2 - 20.1
M8 7T, 8T, 8.8 1.25 16.6 - 21.0 22.6 - 28.4 1.0 19.5 - 25.3 26.5 - 34.3
10T, 10.9, 11T 21.0 - 26.8 28.4 - 36.2 22.4 - 29.7 30.4 - 40.2
4T, 4.8 18.8 - 24.6 25.5 - 33.3 21.0 - 26.8 28.4 - 36.3
M10 7T, 8T, 8.8 1.5 32.5 - 41.2 44.1 - 55.9 1.25 36.2 - 46.3 49.0 - 62.8
10T, 10.9, 11T 39.8 - 51.4 53.9 - 69.9 42.7 - 54.2 57.9 - 73.5
4T, 4.8 27.5 - 34.7 37.3 - 47.1 31.8 - 40.5 43.1 - 54.9
M12 7T, 8T, 8.8 1.75 48.5 - 61.5 65.7 - 83.4 1.25 55.0 - 69.4 74.5 - 94.1
10T, 10.9, 11T 68.0 - 85.4 92.9 - 116 73.1 - 93.3 99.0 - 127
4T, 4.8 46.3 - 59.3 62.8 - 80.4 51.4 - 64.4 69.6 - 87.3
M14 7T, 8T, 8.8 2.0 76.7 - 96.9 104 - 131 1.5 86.1 - 109 117 - 148
10T, 10.9, 11T 102 - 129 139 - 175 108 - 137 147 - 186
4T, 4.8 63.6 - 81.0 83.3 - 110 67.3 - 84.6 91.3 - 115
M16 7T, 8T, 8.8 2.0 110 - 136 149 - 184 1.5 116 - 142 157 - 192
10T, 10.9, 11T 152 - 188 206 - 255 163 - 199 221 - 270
4T, 4.8 106 - 132 144 - 179 127 - 156 172 - 211
M20 7T, 8T, 8.8 2.5 177 - 213 240 - 289 1.5 203 - 246 275 - 333
10T, 10.9, 11T 268 - 325 363 - 441 293 - 358 397 - 485
31-4
SPECIAL TOOLS
PTO Clutch Pack Pressure Testing Fitting

(1/4 BSPT x 7/16--20 UNF--37° Flare) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #CNH299008A, CIH #CAS2789
20034362
1
PTO Clutch Pack Press Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #CNH299009, CIH #CAS2790
20033417
Detent Ball Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #FNH00081, CIH #CAS2788
31-5
Rear live power take-off is standard equipment on all
D35, D40 and D45 tractors. The power take-off
(PTO) system is independent of the driveline and 1
runs directly off of the engine flywheel. The PTO is
engaged and disengaged by a hydraulically oper-
ated PTO clutch system. The operator uses a control
lever, 1, connected to a hydraulic clutch control valve
that is used to pressurize the PTO clutch with hydrau-
lic fluid.
30000422
4
The DX35, DX40 and DX45 only models can be
equipped with a mid PTO system. The mid PTO oper- 1
2
ates off of the same PTO clutch system as the rear
PTO system. Tractors equipped with a mid PTO sys-
tem utilize three PTO levers instead of just one for
tractors equipped with rear PTO only. A control lever,
1, engages and disengages the PTO clutch system,
while the other two levers, 2, select which PTO (rear
or mid) power is sent to. Mid PTO is available as a
dealer installed accessory only.
10997820
5
31-6
1
4
2 3 5 6
20000371
6
Op. 31 110 power flows through the PTO clutch, 4, to the PTO
countershaft, 5. Power is then transferred from the
REAR PTO PTO countershaft, 5, to a fixed 49-tooth gear, 6. The
Power Flow Diagram for the 12 x 12 Synchronized gear, 6, turns the rear PTO shaft, 7, when the PTO is
Shuttle Shift Transmission engaged.
On tractors equipped with a 12 x 12 synchronized
shuttle shift transmission power flows from the en- NOTE: With the tractor shut off, the rear PTO output
gine through a damper disc, 1, through the transmis- shaft, 7, can be rotated slightly, to aid in connection
sion via the PTO driveshaft, 2, to a PTO input shaft, to implement drive shaft, but cannot be rotated in a
3. The PTO input shaft, 3, is connected to the PTO complete revolution.
clutch, 4. When the operator engages the PTO,
31-7
1
2 3 6
4 5 7
8 9
10
20000382
7
Op. 31 110 is engaged, power flows through the PTO clutch, 6,
Power Flow Diagram for the Hydrostatic to the PTO countershaft, 7. Power is then transferred
Transmission (HST) to a fixed 49-tooth gear, 8. When the rear PTO is en-
gaged, a shifter fork engages a sliding gear coupler,
On tractors that are equipped with the hydrostatic
9, that engages the fixed 49-tooth gear to the rear
transmission (HST), power flows from the engine
PTO shaft, 10, causing the shaft to turn.
through a damper disc, 1, to the HST input shaft, 2,
of the HST pump, 3. Power is then routed through the
HST pump, 3, to a PTO shaft, 4, which goes through NOTE: With the tractor shut off, the rear PTO output
the transmission, to the PTO input shaft, 5. The PTO shaft, 10, can be rotated slightly, to aid in connection
input shaft, 5, located in the rear differential housing, to implement drive shaft, but cannot be rotated in a
is connected to the PTO clutch, 6, and when the PTO complete revolution.
31-8
1
2 3 6 7
5 8 9
4
10
14
11
16 13 12
15
18
17
20000383
8
Op. 31 120 mid PTO is engaged, a shifter fork engages a sliding
Power Flow Diagram for Tractors Equipped with gear coupler, 8, with a 21-tooth gear, 9, both of which
a Mid PTO Kit are located on the PTO countershaft, 7. The 21-tooth
gear on the PTO countershaft spins a 39-tooth gear,
The mid PTO system utilizes several components
10, which rotates independently on the rear PTO
common to the rear PTO system. Power flows from
shaft, 11. This 39-tooth gear transfers power to
the engine through a damper disc, 1, to the HST input
another 21-tooth gear, 12, fixed on the upper mid
shaft, 2, of the HST pump, 3. Power is then routed
PTO countershaft, 13. The upper mid PTO counter-
through the HST pump, 3, to a PTO shaft, 4, which
shaft, 13, rotates a 25-tooth gear, 14, that turns a
goes through the transmission to the PTO input shaft,
fixed 33-tooth gear, 15, on the lower mid PTO coun-
5. The PTO input shaft, 5, located in the rear differen-
tershaft, 16. This gear, 15, transfers power to a
tial housing, is connected to the PTO clutch, 6, and
31-tooth gear, 17, which is fixed to the mid PTO shaft,
when the PTO is engaged, power flows through the
18, causing the mid PTO shaft, 18, to turn.
PTO clutch, 6, to the PTO countershaft, 7. When the
31-9
1 2 3
6 2
20000348
9
Op. 31 104 6. The diverter valve diverts 0.8 gallons of the 9.8 gal-
lons per minute capacity of the pump to the PTO sys-
HYDRAULIC FLUID FLOW tem. The remaining flow is utilized by the tractor’s hy-
PTO Clutch Assembly draulic system (Section 35). From the diverter valve,
The PTO clutch engages and disengages by using the hydraulic fluid is transferred to the clutch control
hydraulic fluid from the tractor sump. Hydraulic fluid valve, 7, through the PTO system hydraulic line, 8.
is pumped from the sump, 1, through a suction tube, The clutch control valve controls whether the PTO
2, and filter, 3, to the hydraulic pump, 4. The hydraulic system clutch is engaged or disengaged, as deter-
pump pressurizes the fluid and then is pumped mined by the position of the PTO control lever.
through a hydraulic line, 5, to the PTO diverter valve,
31-10
8
3
9
7
5 4
20044371
10
When the PTO control lever is set to the engage posi- sembly, to the PTO countershaft, 7. When hydraulic
tion, the hydraulic fluid flows into the PTO clutch con- fluid pressure exceeds the relief pressure the clutch
trol valve, 1, through the valve spool, 2, and clutch control valve is set for, the relief valve, 8, opens and
piston fluid supply tube, 3. The hydraulic fluid pushes hydraulic fluid flows through the clutch lubrication
against the clutch piston, 4, which in turn presses the tube, 9, to the clutch assembly. The fluid then exits
clutch discs, 5, together. Power is then transferred the clutch and returns to the hydraulic fluid reservoir.
from the PTO input shaft, 6, through the clutch as-
31-11
2 1
20044370
11
When the PTO control lever is set to the disengage ton, 4, any hydraulic fluid remaining in the clutch pis-
position, the hydraulic fluid flows into the PTO clutch ton is pushed back through the clutch piston supply
control valve, 1, through the valve spool, 2, and di- tube, 5, to the clutch control valve spool, 2. The valve
rectly to the clutch lubrication tube, 3. Hydraulic fluid spool then diverts the hydraulic fluid back into the hy-
flows through the tube and into the clutch assembly, draulic fluid reservoir through a clutch bleed back
lubricating the clutch components. Since there is no port, 6, in the valve body.
hydraulic pressure being supplied to the clutch pis-
31-12
TROUBLESHOOTING
1. Cannot rotate the PTO shaft with PTO control lever at “ON” position
Is the PTO control lever in NO

“ON” position with mid PTO Move to “ON” position
model?
YES
Check the relief valve

pressure.
Is the relief valve pressure as

specified with the PTO NO YES 1. Is the PTO clutch piston
Could the relief valve pressure
control lever at “ON” be adjusted? sticking?
position? 2. Are the clutch discs and/or
separator plates worn?
• 14.2 -- 16.2 bar
(202 -- 230 psi) at the
engine speed 2600 rpm YES
on Model D35
• 17.9 -- 19.9 bar 1. Repair or replace the
(254 -- 283 psi) at the piston.
engine speed 2600 rpm
on Model D40 and D45. 2. Replace the clutch discs
and separator plates as a
set.
NO
1. Suction of air in the 1. Check suction tubes and

system O rings from pump to
YES reservoir.
2. Defective hydraulic pump. 2. Replace the hydraulic
pump.
3. The hydraulic fluid filter 3. Replace the hydraulic fluid
(canister) is clogged. filter (canister).
4. The relief valve is stuck or 4. Repair or replace the relief
worn. valve and clutch control
valve assembly.
5. The relief valve spring is 5. Replace the relief valve
damaged. spring or PTO clutch
control valve assembly.
6. Defective PTO diverter 6. Repair or replace the PTO
valve. diverter valve.
7. Defective seal rings on the 7. Replace the PTO clutch
PTO clutch assembly or O seal rings or hydraulic
rings on the hydraulic fluid tube O rings.
transport tubes.
31-13
PRESSURE TESTING
The hydraulic operating pressure of the PTO clutch Model Transmission Type Below Transmission S/N
is set by the relief valve adjustment, which is located
D35 (12 x 12) 3M44130
on the PTO clutch control valve. If the relief pressure
is set too low, the PTO clutch will not engage com- DX35 HST 3M44132
pletely causing the clutch discs to slip. This will cause D40 (12 x 12) 3M43730
premature wear of the clutch discs and separator DX40 HST 3M43734
plates. If the relief pressure is set to high, the PTO
D45 (12 x 12) 3M43961
clutch components may be damaged from the ex-
cess pressure. DX45 HST 3M43727
Test Procedure (Below Serial Number -- See Chart)

1. Remove the seat and seat brackets from the
tractor.
2. On deluxe model tractors, drive out the roll pin,
1, or remove the split pin which secures the flow
control valve linkage, 2, to flow control valve.
2
1
19998697
12
3. Remove the 6mm hex head plug, 1, from the
PTO clutch control valve, 2. Using special tool # 2
(NH #CNH299008, CIH #CAS2789), install a 0 -
60 bar (0 - 600 psi) pressure gauge and line into 1
this port.
4. Start the engine and operate the hydraulic
system to warm the hydraulic fluid to operating
temperature.
5. Set the engine rpm to full throttle (2600 rpm).
30000424
13
6. Observe the reading on the pressure gauge. The
pressure indication should be:
Model Pressure Reading

D35, DX35 14.2 -- 16.2 bar
(202 -- 230 psi)
D40, DX40, 17.9 -- 19.9 bar
D45, DX45 (254 -- 283 psi)
30000425
14
31-14
7. If required, shut the tractor off and adjust the
relief pressure by removing the 24 mm acorn nut
on the clutch control relief valve and turning the
relief pressure set screw, 1. One-quarter turn
clockwise or counter-clockwise will raise or lower
the pressure by approximately 7 bar (100 psi).
Model Transmission Type On or Above

Transmission S/N
D35 (12 x 12) 3M44130
DX35 HST 3M44132
D40 (12 x 12) 3M43730
1
DX40 HST 3M43734 30000424
D45 (12 x 12) 3M43961 15
DX45 HST 3M43727
Test Procedure (Serial Number and Above --

See Chart)
1. Remove the seat and seat brackets from the
tractor.
2. On deluxe model tractors, drive out the roll pin,
1, or remove the split pin, 1, which secures the
flow control valve linkage, 2, to flow control valve.
1
2
20044373
16
3. Remove the 6mm hex head plug, 1, from the PTO
clutch control valve, 2. Using special tool # (NH
#CNH299008, CIH #CAS2789), install a 0 - 60 bar 2
(0 - 600 psi) pressure gauge and line into this port. 1
system to warm the hydraulic fluid to operating
temperature.
5. Set the engine rpm to full throttle (2600 rpm).
20044372
17
31-15
6. Observe the reading on the pressure gauge. The
pressure indication should be:

D35, DX35 14.2 -- 16.2 bar
(202 -- 230 psi)
D40, DX40, 17.9 -- 19.9 bar
D45, DX45 (254 -- 283 psi)
30000425
18
7. If required, shut the tractor off and adjust the relief
pressure by removing the plug, 1, on the clutch
control relief valve and change the pressure by
adding or removing adjusting shims, 2. Each 1
mm shim change will raise or lower the relief
pressure by approximately 1.21 bar (17.5 psi).
20044374
2
19
31-16
OVERHAUL
Op. 31 104 82
PTO SYSTEM DIVERTER VALVE

4 5
ASSEMBLY
Removal 3 2
1. Disconnect the relief valve to sump return line, 1,
at the valve body fitting.
2. Remove the bolts securing the pump pressure
line, 2, and the control valve pressure line, 3, at
the valve assembly.
3. Remove the PTO system hydraulic line, 4, at the
PTO diverter valve body fitting, 5.
1
10998381
20
4. Remove the bolt, 1, securing the valve assembly
to the tractor. Cap and plug all openings. 1
10996435
21
Disassembly
2
1. Separate the PTO diverter valve body, 1, from 1
the relief/diverter valve assembly, 2, by removing
the three retaining bolts, 3, securing the two
valve assemblies together.
10998804
22
31-17
2. Remove the diverter valve plugs, 5 and 6, with
the O rings, 4. 5 1
3. Remove the diverter spool, 2, and spring, 3, from
the valve body, 1.
2
Inspection 4 3
1. Clean and inspect the diverter valve spool and 6
valve body bore for excess wear or score marks.
2. Inspect the spring for wear or damage.
3. Replace the PTO diverter valve as an assembly
if found to be damaged. 4
20000435
23
1. PTO Diverter Valve Body
2. Valve Spool
3. Spring
4. O ring
5. Plug
6. Plug
Assembly
5 1
1. Using a new O ring, 4, install plug, 5, in one end
of the valve body, 1.
2. Install the spool, 2, and spring, 3, into the valve
body. 2
3. Using a new O ring, 4, install plug, 6, into the 4 3
open end of the diverter valve. 6
4
20000435
24
4. Using a new O ring, 4, between the PTO diverter
valve body, 1, and the diverter/relief valve body, 2
2, secure the valves together using the three 1
bolts, 3. 4 3
3
10998805
25
31-18
Installation
1. Install new O rings on the pump pressure line and 1
the pressure line to control valve.
2. Install the bolt, 1, which secures the valve
assembly to the tractor. Do not tighten the bolt at
this time.
10996435
26
3. Install the PTO system supply line, 4, and the
sump return line, 1. Do not tighten fittings at this 4 5
time.
3 2
4. Install the bolts and nut securing the pump
pressure line, 2, and the control valve pressure
line, 3, to the valve assembly.
5. Tighten all loose bolts and fittings to torque
specifications listed in the back of this section.
1
10998381
27
31-19
Op. 31 104 82
PTO CLUTCH CONTROL VALVE
(Below Serial Number -- See Chart)
Model Transmission Type Below Transmission S/N

D35 (12 x 12) 3M44130
DX35 HST 3M44132 2
D40 (12 x 12) 3M43730
DX40 HST 3M43734 1
D45 (12 x 12) 3M43961
DX45 HST 3M43727 19998697
28
Removal
1. On deluxe and economy model tractors, remove
the seat and seat brackets.
2. On deluxe model tractors, separate the flow control
valve linkage, 1, from the lift cover by using a
hammer and suitable punch to remove the roll pin,
2, or remove the split pin (if equipped).
3. Disconnect the PTO system hydraulic line, 1,
from the clutch control valve, 2. 6
4. Using a hammer and suitable punch, remove the
roll pin, 3, that secures the PTO control lever
linkage, 4, to the clutch control valve, 2.
5. Remove the three bolts, 5, that secure the clutch
control valve, 2, to the tractor differential, 6.
5
1
4
2
5
3
30000350
29
NOTE: When removing the clutch control valve, the
hydraulic fluid transport tubes may be removed with 1 1
the valve. The O rings, 1, used on the tubes, 2, will
need to be replaced before installing the valve back
onto the differential housing.
2 2
6. Remove the clutch control valve from the

differential.
30000362
30
31-20
3
4
5
2 4
1 13
12
11
10
9
8
14 7
6
20000436
31
1. Valve Body 8. Jam Nut
2. E-Clip 9. Copper Gasket
3. Valve Spool 10. Relief Pressure Adjustment Screw
4. O Ring 11. Relief Spring
5. E-Clip 12. Relief Poppet
6. Acorn Nut 13. Poppet Seat
7. Dust Washer 14. Relief Valve Assembly
SPOOL
Removal
1. Remove the E-clip, 2, securing the valve spool,
3, in the valve body, 1.
2. Using a brass drift, gently tap the valve spool, 3,
out of the valve body, 1.
3. Remove the E-clip, 5, from the valve spool, 3.
Inspection
1. Remove and discard all O rings.
2. Clean and inspect the valve spool and the spool
bore for pitting, scratches, or excess wear. If
found to be defective, replace the clutch control
valve assembly.
Assembly
1. Sparingly lubricate new O rings, 4, with
petroleum jelly and install them onto the valve
spool, 3.
31-21
3
2
1
3
4
30000364
30000370
32
NOTE: The valve spool must be installed with clutch CAUTION
bleed back recess, 4, towards the bottom of the valve
Due to minimal diameter tolerances between the
spool bore or the PTO clutch will not operate
valve spool bore and the valve spool, it is necessary
properly.
to chill the valve spool in a freezer or other cooling
device prior to inserting the valve spool into spool
2. Lightly scribe the valve body and valve spool with bore. Failure to do so may result in damage to the
aligning lines, 3. These will be used to reference valve spool, valve body, or O rings.
the correct position of the valve spool if the spool
is rotated after the spool has been installed into
the valve body. 4. Install the valve spool, 1, into the valve body, 2.
3. Lubricate the spool bore with clean hydraulic 5. Install the E-clips, 2 and 5, Figure 31, onto the
fluid. valve spool.
6. Check that the spool moves freely in the spool
bore. If it does not, replace the clutch control
valve assembly.
31-22
3
4
5
2 4
1 13
12
11
10
9
8
14 7
6
20000436
33
1. Valve Body 8. Jam Nut
2. E-Clip 9. Copper Gasket
3. Valve Spool 10. Relief Pressure Adjustment Screw
4. O ring 11. Relief Spring
5. E-Clip 12. Relief Poppet
6. Acorn Nut 13. Poppet Seat
7. Dust Washer 14. Relief Valve Assembly
CLUTCH CONTROL RELIEF VALVE 2. Inspect the spring for any distortion, replace the
valve if found to be defective.
Disassembly
3. Discard the copper gasket, 9.
1. Remove the acorn nut, 6, and the dust washer,
7, from the relief valve assembly, 14. 4. Inspect the dust washer, 7, for deterioration.
Replace as needed.
2. Loosen the relief pressure adjustment jam nut, 8,
and remove the relief pressure adjustment
screw, 10, from the valve body, 1. Assembly
3. Remove the copper gasket, 9, from the valve 1. Install the poppet seat, 13, into the valve body, 1,
body, 1. using a large screwdriver.
4. Remove the relief spring, 11, and relief poppet, 2. Install the relief valve poppet, 12, and spring, 11,
12, from the valve body, 1. into the valve body, 1.
5. Using a large screwdriver, carefully remove the 3. Screw the relief pressure adjustment screw, 9,
poppet seat, 13, from the valve body, 1. into the valve body, 1.
4. Install the new copper gasket, 9, and install the
Inspection jam nut, 8, onto the pressure adjustment screw,
10.
1. Clean and inspect the relief poppet, the poppet
seat, and the relief valve bore for scratches, 5. Install the dust washer, 7, and the acorn nut, 6.
pitting, excess wear, or other damage. If any
damage is found, replace the clutch control
valve.
31-23
Installation
1. Discard and replace all O rings, 1, which seal the
clutch control valve to the differential housing.
1
1
30000362
34
2. Install the control valve onto the differential
housing. Install the three bolts, 5, that secure the 6
control valve, 2, to the differential housing, 6. Do
not tighten at this time.
3. Connect the PTO system hydraulic line, 1, to the
clutch control valve, 2.
4. Align the scribe marks previously made on the
5
valve body and spool. Connect the PTO control
lever linkage, 4, and drive the roll pin, 3, back into
the linkage and spool.
5. Tighten the bolts, 5, which secure the valve, 2, to 1
the differential housing, 6. Torque bolts to
4
specifications listed in the rear of this section.
2
6. Reference the PTO pressure testing chapter in 5
this section and adjust the PTO clutch control
relief valve according to specifications. 3
7. Install the seat brackets and seat back onto the 30000350
tractor.
35
31-24
Op. 31 104 82
PTO CLUTCH CONTROL VALVE

(Serial Number On or Above -- See Chart)
Model Transmission Type On or Above
Transmission S/N
D35 (12 x 12) 3M44130
DX35 HST 3M44132
1
D40 (12 x 12) 3M43730
DX40 HST 3M43734 2
D45 (12 x 12) 3M43961
DX45 HST 3M43727 20044373
36
Removal
1. On deluxe and economy model tractors, remove
the seat and seat brackets.
2. On deluxe model tractors, separate the flow
control valve linkage, 1, from the lift cover by using
a hammer and suitable punch to remove the roll
pin, 2, or remove the split pin (if equipped).
3. Disconnect the PTO system hydraulic line, 1,
from the clutch control valve, 2. 6
4. Using a hammer and suitable punch, remove the
roll pin, 3, that secures the PTO control lever
linkage, 4, to the clutch control valve, 2.
5. Remove the three bolts, 5, that secure the clutch
control valve, 2, to the tractor differential, 6. 5
1
4
2
5
3
20044375
37
NOTE: When removing the clutch control valve, the
hydraulic fluid transport tubes may be removed with 1 1
the valve. The O rings, 1, used on the tubes, 2, will
need to be replaced before installing the valve back
2 2
6. Remove the clutch control valve from the

differential.
20044376
38
31-25
20044377
39
1. Valve Body 8. Spacer
2. Snap Ring 9. Spacer
3. Valve Spool 10. Spring
4. Snap Ring 11. O ring
5. Shims 12. O ring
6. Plug 13. O ring
7. Poppet
Disassembly Inspection
1. Remove the snap ring, 2, and spacer, 8, securing 1. Remove and discard all O rings.
the valve spool, 3, in the valve body, 1.
2. Clean and inspect the valve spool and the spool
2. Using a brass drift, gently tap the valve spool, 3, bore for pitting, scratches, or excess wear. If
out of the valve body, 1. found to be defective, replace the clutch control
valve assembly.
3. Remove the spacer, 9, and snap ring, 4, from the
valve spool, 3. 3. Clean and inspect the poppet and poppet bore
for pithing, scratches or excess wear. Replace
4. Remove the plug, 6, shims, 5, spring, 10, and
control valve as necessary.
poppet, 7, from the valve body, 1.
4. Inspect the spring for any distortion. Replace
control valve spring as necessary.
NOTE: Shims are installed between spring and plug.
Confirm thickness and quantity during disassembly. Assembly
1. Sparingly lubricate new O rings, 11, with
petroleum jelly and install them onto the valve
spool, 3.
31-26
NOTE: The valve spool must be installed with the flat
face, 4, towards the top of the valve or the PTO clutch
will not operate properly.
2. Lightly scribe the valve body and valve spool with

aligning lines, 3. These will be used to reference
the correct position of the valve spool if the spool
is rotated after the spool has been installed into
the valve body.
3. Lubricate the spool bore with clean hydraulic
fluid.
CAUTION 20044378
Due to minimal diameter tolerances between the 40

valve spool bore and the valve spool, it is necessary
to chill the valve spool in a freezer or other cooling
device prior to inserting the valve spool into spool
bore. Failure to do so may result in damage to the
valve spool, valve body, or O rings.
4. Install the valve spool, 3, into the valve body, 1.

5. Install the spacers, 8 and 9, snap rings, 2 and 5,
onto the valve spool.
6. Check that the spool moves freely in the spool
bore. If it does not, replace the clutch control
valve assembly.
7. Install the poppet, 7, spring, 10, shims, 4, and
plug, 6, for the relief valve, into the vale body.
20044377
41
Item # Description Tightening Torque

N⋅m (Ft. lbs.)
1 Plug 29 (21)
2 Plug 15 (10.8)
3 Adapter 15 (10.8)
20044379
42
31-27
Installation
1. Discard and replace all O rings, 1, which seal the
clutch control valve to the differential housing.
20044377
43
2. Install the control valve onto the differential
housing. Install the three bolts, 5, that secure the 6
control valve, 2, to the differential housing, 6. Do
not tighten at this time.
3. Connect the PTO system hydraulic line, 1, to the
clutch control valve, 2.
4. Align the scribe marks previously made on the 5
valve body and spool. Connect the PTO control
lever linkage, 4, and drive the roll pin, 3, back into
the linkage and spool.
5. Tighten the bolts, 5, which secure the valve, 2, to 1
the differential housing, 6. Torque bolts to 4
specifications listed in the rear of this section.
2
6. Reference the PTO pressure testing chapter in 5
this section and adjust the PTO clutch control 3
relief valve according to specifications.
7. Install the seat brackets and seat back onto the 20044375
tractor.
44
31-28
Op. 31 114 62
PTO CLUTCH
Removal 2
1. Separate the rear differential housing from the
transmission. Refer to Section 27, “Rear Axle”. 1
2. Remove the 12 bolts, 1, that secure the PTO
clutch cover, 2, to the rear differential housing, 3,
and lift the cover off.
3
20044380
45
3. Remove the hydraulic transport tubes, 1, from
the hydraulic fluid distribution block, 2, of the 1
clutch assembly.
2
50042607
46
NOTE: On tractors equipped with a mid PTO, the mid
PTO detent spring, 1, is located between the lift cover
assembly and the rear differential housing. When
removing the lift cover make sure that the spring
does not fall into the rear differential or is lost.
NOTE: Rear axle and brake assemblies have been

removed for photograph.
2
4. Remove the 16 nuts and bolts securing the lift

cover, 2, to the rear differential housing, 3. Using 1
a suitable lifting device, lift the lift cover off of the
rear differential housing.
20000366
47
31-29
5. Remove the rear PTO countershaft bearing seal,
1, from the rear differential housing, 2.
1
30000385
48
6. Remove the snap ring, 1, that secures the PTO
countershaft bearing, 2, in the rear differential 2 1
housing, 3.
30000356
49
7. For tractors equipped with mid PTO, remove the
snap ring, 1, that retains the gear coupler, 2, on
the PTO countershaft, 3. 2
1
30000399
3
50
31-30
8. Insert a suitable brass or aluminum drift, 1,
through the front of the PTO clutch input shaft, 2,
and use a hammer to drive the PTO countershaft
out of the PTO clutch assembly, 3.
3
1
30000357
51
9. Slide the PTO countershaft, 1, towards the rear
of the differential housing, so that it is completely
free from the clutch assembly, 2. 1
2
50044344
52
10. Remove the two bolts, 1, securing the PTO clutch
brake stopping plate, 2, to the differential 2
housing, 3.
3
50044345
53
31-31
11. Remove the two bolts, 1, retaining each side of
the clutch assembly, 2, to the inside of the 2 3
30000360
54
12. Slide the PTO clutch, 1, rearward in the
differential housing and lift the clutch assembly 1
out of the rear differential housing, 2. 2
30000361
55
Op. 31 114 68
Disassembly
1. Prior to disassembly, use a feeler gauge to check
the air gap between the clutch backing plate and the
snap ring that retains the clutch pack in place. Air
gap specification: 1.5 -- 2.5 mm (0.059 -- 0.098″).
30000390
56
31-32
WARNING
Special tool (NH #CNH299009, CIH #CAS2790)
must be used to compress the piston spring and
backing washer, otherwise bodily injury may
occur when removing the snap ring.
2. Place the clutch assembly in a hydraulic press;

apply pressure to the spring backing washer, 1,
and piston spring using special tool, 2. (NH 2
#CNH299009, CIH #CAS2790). While pressure
is being applied to the washer and spring, re-
move the snap ring, 3, from the clutch housing.
Slowly relieve pressure from the backing washer
and spring.
3
1
30000374
57
3. Remove the snap ring, 1, retaining the clutch
pack and piston, 2, in the PTO clutch housing, 3.
Slide the clutch pack and piston off of the clutch
housing.
3
30000375
58
4. Remove the snap ring, 1, which secures the hy-
1
draulic fluid distribution block, 2, to the PTO
clutch housing, 3, and slide the block off of the
clutch housing.
30000376
59
31-33
5. Remove the snap ring, 1, retaining the brake disc
and brake pressure plates, 2, to the clutch hous-
ing, 3. 3
IMPORTANT: Pay close attention to the orientation

of the brake disc stop tab. The stop tab has a straight
edge and a tapered edge. The straight edge must
contact the stop plate when installed in the tractor.
1
2
30000377
60
Inspection
1. Remove and discard all O rings, 1, on each hy-
draulic fluid transport tube, 2, and replace with
new O rings. 2
1 1
20000391
61
2. Remove the seal rings, 1, from the clutch hous-

ing, 2, and inspect them for excess wear and 2
damage. Replace as needed.
30000378
62
31-34
3. Remove the seal ring, 1, from the clutch piston,
2, and inspect the ring for excess wear and dam-
age. Replace as needed.
2
1
30000380
63
4. Inspect each clutch disc, 1, for thickness, dam-
age, or excess wear. Replace if the thickness of
the discs is less than 1.8 mm (0.071″).
5. Lay each clutch disc separator plate and the

clutch backing on a plate of glass or other flat sur-
face and inspect them for any warpage, excess 1
wear, or damage. Replace as needed.
30000382
64
6. Inspect the clutch brake disc, 1, thickness and re-
place the brake disc if damaged or if the thick-
ness is less than 1.8 mm (0.071″).
7. Inspect the brake pressure plates for warpage,

excess wear, or damage. Replace as needed.
8. Clean and inspect the clutch housing, piston,

spring, and distribution block for excess wear or 1
damage. Replace the clutch assembly if any of
these are found to be damaged or show excess
wear.
30000381
65
31-35
Assembly
2
NOTE: Prior to assembly of the PTO clutch, soak the
clutch discs, brake disc, and seal rings in clean hy-
draulic fluid for a minimum of one hour.
1. Install the seal rings, 1, onto the clutch housing,

2.
1
30000378
66
NOTE: When installing the snap ring that secures the
PTO brake components, make sure that the gap in
the snap ring is 45° from brake pressure plate re- 3
cesses in the clutch housing.
2. Place a brake pressure plate, 1, and brake disc,

2, onto the clutch housing, 3. Place the remaining
brake pressure plate, 1, on top of the brake disc.
Secure the plates and disc with the snap ring, 4.
IMPORTANT: Be sure to install the brake disc with 4

the stop tab in the proper orientation.
1 2
30000377
67
3. Slide the distribution block, 2, over the clutch
1
housing, 3, and retain the block with the snap
ring, 1.
30000376
68
31-36
4. Install the seal ring, 1, onto the clutch piston, 2.
1
30000380
69
NOTE: When installing the clutch piston, the side of
the clutch piston with the seal ring is installed into the 1
clutch housing first.
5. Slide the clutch piston, 1, onto the clutch housing,

2.
30000379
70
NOTE: When installing the clutch discs and separa-
tor plates onto the clutch housing, install the thick
backing plate last. (On top)
2
6. Install clutch separator plates, 1, and clutch
discs, 2, on top of the clutch piston. Start with a
separator plate and alternate the clutch discs
with the separator plates until all plates and discs
are installed. Install thick backing plate, 3, last.
1
3
20000367
71
1. Separator Plate
2. Clutch Disc
3. Backing Plate
31-37
NOTE: The snap ring that secures the clutch pack to
the clutch housing is chamfered on one inside edge.
Install this edge to the inside of the clutch assembly.
CHAMFERED
EDGE
20000368
72
NOTE: When installing the snap ring that secures the
clutch pack to the clutch housing, place the gap in the 45°
snap ring 45° from a clutch piston relief in the clutch
housing.
20000369
73
7. Install the snap ring, 1, that retains the clutch
pack and piston, 2, in the PTO clutch housing, 3.
3
30000375
74
31-38
8. Place the piston spring, 1, and backing washer,
2, onto the clutch housing. 2
30000392
75
WARNING
Special tool (NH #CNH299009, CIH #CAS2790)
must be used to compress the piston spring and
backing washer, otherwise bodily injury may
occur when installing the snap ring.
9. Place the clutch assembly in a hydraulic press

and using special tool (NH #CNH299009, CIH
#CAS2790), 2, apply pressure to the spring and 2
backing washer, 1. Install the snap ring, 3, that re-
tains the spring and washer to the clutch housing.
3
1
30000374
76
10. Use a feeler gauge to check the air gap between
the clutch backing plate and the snap ring that re-
tains the clutch pack in place. Air gap specifica-
tion: 1.5 -- 2.5 mm (0.059 -- 0.098″).
30000390
77
31-39
Op. 31 114 62
Installation 1
1. Position the PTO clutch, 1, into the differential
housing and engage the clutch teeth with the
splines on the PTO input shaft, 2. Be sure that all
three clutch discs are engaged with the input 2
shaft.
30000393
78
2. Install the two bolts, 1, that secure the clutch
assembly, 2, to the inside of the differential 2 3
housing, 3.
30000360
79
3. Align the brake disc tab, 1, as shown to the brake
disc stopping plate, 2, and install the two bolts, 3,
securing the plate to the differential housing. 1
3 2
50044346
80
31-40
4. Using a hammer and suitable drift, drive the PTO
countershaft, 1, into the clutch assembly and
1
30000407
81
5. For tractors equipped with mid PTO, install the
snap ring, 1, that retains the gear coupler, 2, on
the PTO countershaft, 3. 2
1
30000399
3
82
6. Install the snap ring, 1, that secures the PTO
housing, 3.
30000356
83
31-41
7. Install a new bearing seal, 1, into the differential
housing, 2.
1
30000385
84
8. Install the hydraulic fluid transport tubes, 1, into
the hydraulic fluid distribution block, 2, of the 1
clutch assembly.
2
50042607
85
9. Apply a small bead of LocTite RTV silicone
gasket maker to the clutch cover, 2, and
differential housing, 3. Secure the cover to the
differential housing with the 12 bolts, 1. Tighten 2
the bolts to torque specifications listed in the
back of this chapter.
1
3
20044380
86
31-42
installing the lift cover, be sure that this spring is
installed also.
NOTE: On tractors equipped with a mid PTO, make

sure that the mid PTO arm engages the mid PTO
2
shifter rail in the differential housing when installing
the lift cover.
1
10. Apply a small bead of LocTite RTV silicone
gasket maker to the lift cover and differential
housing. Install the hydraulic lift cover onto the
differential housing. Tighten bolts to torque
20000366
87
31-43
Op. 31 114 42
POWER TAKE OFF SYSTEM FOR 12 X 12
SYNCHRONIZED SHUTTLE SHIFT
TRANSMISSION 2
Removal 1
1. Separate the tractor between the transmission
and the rear differential housing. Refer to Section
27, “Rear Axle”.
clutch cover, 2, to the rear differential housing, 3, 3
and lift the cover off. 20044380
NOTE: Rear axle and brake assemblies have been 88


cover to the rear differential housing. Using a
suitable lifting device, lift the lift cover off of the
rear differential.
PTO INPUT SHAFT

Removal 1
1. Remove the PTO clutch from the rear differential
housing.
2. Using a suitable drift and hammer carefully drive
the PTO input shaft, 1, rearwards in the
differential housing and lift the shaft out.
30000394
89
31-44
7
6
5
4
3
2
1
20000384
90
1. Bearing Holder 5. Internal Snap Ring
2. Front Bearing 6. Input Shaft
3. Snap Ring 7. Rear Bearing
4. Bearing
3. Once the PTO input shaft assembly has been 2. Inspect all parts for excessive wear and damage.
removed, the bearing holder, 1, can be driven out Replace as needed.
the front of the differential housing from the inside
3. Check all bearings for uneven rotation when
the housing.
turned by hand.
4. Lubricate bearings in clean hydraulic oil before
Disassembly
assembly.
1. Remove the front bearing, 2, from the shaft, 6.
2. Using snap ring pliers, remove the snap ring, 3, Assembly
from the shaft.
1. Install rear bearing, 7, in the bore of the PTO
3. Remove the large bearing, 4, from the shaft. input shaft, 6.
4. Using snap ring pliers, remove the small internal 2. Install the small internal snap ring, 5, in the bore
snap ring, 5, from the PTO input shaft bore. of the shaft.
5. Remove the rear bearing, 7, from the bore of the 3. Drive the large bearing, 4, onto the shaft.
shaft.
4. Install the snap ring, 3, onto the shaft.
5. Drive the front bearing, 2, onto the shaft.
Inspection
1. Clean all parts in a suitable solvent and allow to 6. Drive the bearing holder, 1, into the front of the
air dry. differential housing.
31-45
Installation
1. Place the PTO input shaft, 1, into the differential
housing and use a suitable drift, 2, to drive the 1 2
shaft into place.
2. Install the PTO clutch assembly.
30000406
91
Op. 31 114 46 / 31 114 19
PTO COUNTERSHAFT AND REAR PTO
SHAFT
Removal
1. Remove the four bolts, 1, retaining the rear PTO 1
cover, 2, and oil seal to the rear differential
housing, 3. Pry the cover off of the differential. 2
3
30000385
92
1, from the rear differential, 2.
1
30000385
93
31-46
housing, 3.
30000356
94
3
1
30000357
95
5. Slide the PTO counter shaft, 1, out the rear of the
2
30000358
96
31-47
6. Pull on the rear PTO shaft, 1, and remove the
front bearing from the shaft.
30000388
97
7. Remove the 49-tooth gear, 1, from the rear PTO
shaft, 2. Slide the shaft out the rear of the
1
30000387
98
Op. 31 114 46
3
COUNTERSHAFT
Disassembly 2
1. Remove the front PTO countershaft bearing, 1, 1 5
from the inside of the differential housing, 6. 4
2. Remove the rear bearing, 3, from the counter-
shaft, 2.
20000395
99
1. Front Bearing
2. PTO Countershaft
3. Rear Bearing
4. Snap Ring
5. Bearing Seal
6. Differential Housing
31-48
3. Remove the rear bearing, 4, from the rear PTO
shaft, 3. 6
5
4
Inspection
1. Remove and discard the oil seal, 5, from the PTO 3
shaft seal cover, 7. 2 8
1 7
2. Remove any remaining gasket, 6, from the seal
cover, 7, and the differential housing, 9.
air dry.
4. Inspect all parts for excessive wear and damage. 9
Replace as needed.
turned by hand.
6. Lubricate bearings in clean hydraulic fluid before
assembly. 20000396
100
1. Front Bearing
2. 49-Tooth Gear
3. Rear PTO Shaft
4. Rear Bearing
5. Oil Seal
6. Gasket
7. PTO Shaft Seal Cover
8. PTO Shaft Cover
Assembly
1. Install the rear PTO shaft front bearing, 1, and the
PTO countershaft front bearing, 2, inside the
1
30000397
101
31-49
2. Drive the rear bearing, 4, onto the PTO shaft, 3.
6
3. Install a new oil seal, 5, into the PTO shaft seal 5
cover, 7. 4
3
2 8
1 7
20000396
102
1. Front Bearing
2. 49-Tooth Gear
3. Rear PTO Shaft
4. Rear Bearing
5. Oil Seal
6. Gasket
7. PTO Shaft Seal Cover
8. PTO Shaft Cover
4. Drive the PTO countershaft bearing, 3, onto

countershaft, 2. 3
2
1 5
4
20000395
103
1. Front Bearing
2. PTO Countershaft
3. Rear Bearing
4. Snap Ring
5. Bearing Seal
31-50
Installation
NOTE: When installing the 49-tooth gear onto the
rear PTO shaft, be sure that the side of the gear with
the large collar faces the front of the differential
housing. 2
1. Lower the 49-tooth gear, 1, into the differential

housing and install the gear onto the rear PTO
shaft, 2, as the shaft is being inserted into the
1
30000387
104
2. Align the rear PTO shaft, 1, into the front bearing
and using a hammer and suitable drift, drive the
PTO shaft into the front bearing.
3. Insert the PTO countershaft into the differential
housing.
30000432
105
4. Using a hammer and suitable drift, drive the PTO
countershaft, 1, into the PTO clutch and
1
30000407
106
31-51
housing, 3.
30000356
107
6. Install a new rear PTO countershaft bearing seal,
1, into the rear differential housing, 2.
1
30000385
108
7. Place a new gasket between the rear differential
housing, 3, and the PTO shaft seal cover, 2, and
install the four bolts, 1, which secure the cover to
the differential. Torque the bolts to bolt torque
8. Install the PTO clutch cover and lift cover, 1
applying LocTite RTV on the sealing surfaces.
Tighten nuts and bolts to torque specifications 2
listed in the back of this section.
3
9. Assemble the differential and transmission and
install onto the tractor.
30000385
109
31-52
POWER TAKE OFF SYSTEM FOR

HYDROSTATIC TRANSMISSION (HST)
Op. 31 114 00 2
Removal
1
1. Separate the tractor between the transmission
and the rear differential housing. Refer to Section
27, “Rear Axle”.
clutch cover, 2, to the rear differential housing, 3, 3
and lift the cover off.
20044380
110
removing the lift cover make sure that the spring
does not fall into the rear differential or is lost.
NOTE: Rear axle and brake assemblies have been

2

cover, 2, to the rear differential housing, 3. Using 1
a suitable lifting device, lift the lift cover off of the
rear differential.
20000366
111
Op. 31 114 42
PTO INPUT SHAFT 1
Removal
1. Remove the PTO clutch from the rear differential
housing.
2. Using a hammer and suitable drift, carefully drive
the PTO input shaft, 1, rearwards in the
differential housing and lift the shaft out.
30000394
112
31-53
7
6
5
4
3
2
1
20000384
113
1. Bearing Holder 5. Internal Snap Ring
2. Front Bearing 6. Input Shaft
4. Bearing
3. Once the PTO input shaft assembly has been 3. Check all gears for chipped or missing teeth.
removed, the bearing holder, 1, can be driven out Replace as needed.
the front of the differential housing from the inside
the housing.
turned by hand.
5. Lubricate bearings in clean hydraulic oil before
Disassembly
assembly.
1. Remove the front bearing, 2, from the shaft, 6.
2. Using snap ring pliers, remove the snap ring, 3, Assembly
from the shaft.
1. Install the rear bearing, 7, in the bore of the PTO
3. Remove the large bearing, 4, from the shaft. input shaft, 6.
4. Using snap ring pliers, remove the small internal 2. Install the small internal snap ring, 5, in the bore
snap ring, 5, from the PTO input shaft bore. of the shaft.
5. Remove the rear bearing, 7, from the bore of the 3. Drive the large bearing, 4, onto the shaft.
shaft.
4. Install the snap ring, 3, onto the shaft.
5. Drive the front bearing, 2, onto the shaft.
Inspection
1. Clean all parts in a suitable solvent and allow to 6. Drive the bearing holder, 1, into the front of the
air dry. differential housing.
2. Inspect all parts for excessive wear and damage.

Replace as needed.
31-54
Installation
1. Place the PTO input shaft, 1, into the differential
housing and use a suitable drift, 2, to drive the 1 2
shaft into place.
2. Install the PTO clutch assembly.
30000406
114
Op. 31 114 46 / 31 114 19
PTO COUNTERSHAFT AND REAR PTO
SHAFT
Removal
1. Remove the four bolts, 1, retaining the rear PTO 1
cover, 2, and oil seal to the rear differential
housing, 3. Pry the cover off of the differential. 2
3
30000385
115
1, from the rear differential, 2.
1
30000385
116
31-55
housing, 3.
30000356
117
4. Using a magnet, remove the detent ball, 1, for the
mid PTO shifter rail.
30000434
118
5. Using a hammer and suitable punch, drive the
roll pin, 1, that secures the mid PTO engagement 1 3
2
fork, 2, to the mid PTO shifter rail, 3. Remove the
fork and rail from the differential.
30000398
119
31-56
6. Remove the snap ring, 1, that retains the gear
coupler, 2, to the PTO countershaft, 3.
2
1
30000399
3
120
3
1
30000357
121
8. While holding the snap ring, 1, and the gear
coupler, 2, slide the PTO countershaft, 3, out the
back of the differential housing.
3
1
2
30000400
122
31-57
9. Use a hammer and suitable punch to drive out
the roll pin, 1, that secures the rear PTO 2 1
engagement fork, 2, to the rear PTO shifter rail,
3. Remove the fork from the rail, but do not
remove the rail from the differential housing.
30000401
123
10. Using snap ring pliers, remove the snap ring, 1,
that retains the 39-tooth gear, 2, on the rear PTO 2
shaft, 3.
1
30000402
124
11. Lift the 49-tooth gear, 1, gear coupler, 2, snap
ring, 3, and the 39-tooth gear, 4, out the top of the
differential housing as the rear PTO shaft, 5, is
being removed from the back of the differential
housing.
5
4 3 2 1
30000403
125
31-58
Op. 31 114 42
Disassembly
1. Remove the front PTO countershaft bearing, 1,
and the front PTO shaft bearing, 2, from the
inside of the differential housing.
1
2
30000397
126
2. Remove the rear bearing, 8, from the PTO
countershaft, 3. 7
6
3. Remove the thrust washer, 7, from the 5
countershaft, 3. 4
3
4. Remove the 21-tooth gear, 6, and the needle 10
2
bearings, 5, from the PTO countershaft, 3. 1 9
8
11
20000404
127
1. Front Bearing
2. Snap Ring
3. PTO Countershaft
4. Gear Coupler
5. Needle Bearing
6. 21-Tooth Gear
7. Thrust Washer
8. Rear Bearing
9. Snap Ring
10. Bearing Seal
31-59
11
10
9
8
7
6
5
4
3
2
1
12
20
19
18
17
16
15
14
20000405
13
128
1. Front Bearing 11. 39-Tooth Gear
2. Bearing 12. Differential Housing
3. Snap Ring 13. Snap Ring
4. Shaft Collar 14. Bearing
5. 49-Tooth gear 15. Rear PTO Shaft
7. Bearing 17. Oil Seal
8. Gear Coupler 18. Gasket
9. Snap Ring 19. PTO Shaft Seal Cover
10. Bearing 20. PTO Shaft Cover
31-60
5. Remove the bearings, 2 and 7, from the 49-tooth 3. Check all gears for chipped or missing teeth.
gear, 5. Replace as needed.
6. Remove the snap rings, 3 and 6, from the 4. Check all bearings for uneven rotation when
49-tooth gear, 5. turned by hand.
7. Remove the shaft collar, 4, from the 49-tooth 5. Lubricate bearings in clean hydraulic oil before
gear, 5. assembly.
8. Remove bearing, 16, from the rear PTO shaft,
15. Assembly
9. Remove the bearings, 10 and14, from the 1. Install the snap ring, 13, into the 39-tooth gear,
39-tooth gear, 11. 11.
10. Remove the snap ring, 13, from the 39-tooth 2. Install the bearings, 10 and 14, into the 39-tooth
gear, 11. gear, 11.
3. Place the shaft collar, 4, inside the 49-tooth gear,
Inspection 5, and install the snap rings, 3 and 6, into the
gear, 5.
air dry. 4. Install the bearings, 2 and 7, into the 49-tooth
gear, 5.
Replace as needed. 5. Install bearing, 16, onto the rear PTO shaft, 15.
31-61
6. Install the front PTO counter shaft bearing, 1, and
the front PTO shaft bearing, 2, into the differential
housing.
2
30000397
129
NOTE: When assembling the PTO countershaft, 3,
the 21-tooth gear, 6, is installed onto the shaft so the 7
small engaging teeth face forward when the shaft is 6
5
installed into the differential housing. 4
3
7. Install the needle bearings, 5, onto the PTO 2 10
countershaft, 3. 1 9
8
8. Install the 21-tooth gear, 6, onto the PTO
countershaft, 3.
NOTE: When installing the thrust washer, be sure
that the grooves in the washer are facing towards the
21-tooth gear.
9. Install the thrust washer, 7, onto the countershaft, 11

3.
10. Install the rear bearing, 8, onto the countershaft,
3.
20000404
130
1. Front Bearing
2. Snap Ring
3. PTO Countershaft
4. Gear Coupler
5. Needle Bearing
6. 21-Tooth Gear
7. Thrust Washer
8. Rear Bearing
9. Snap Ring
10. Bearing Seal
31-62
Op. 31 114 19
Installation
NOTE: When installing the 39-tooth gear, 4, onto the
rear PTO shaft, 5, be sure that the side of the gear
with the protruding bearing is facing the rear of the
NOTE: When installing the gear coupler, 2, and the

49-tooth gear, 1, be sure they are installed so that
they engage each other.
5
1. Lower the 39-tooth gear, 4, the snap ring, 3, that 4 3 2 1
30000403
retains it, the gear coupler, 2, and the 49-tooth
gear, 1, into the differential housing and install 131
them onto the rear PTO shaft, 5, as it is being
inserted into the rear of the differential housing.
2. Align the rear PTO shaft with the front bearing
and use a suitable drift and hammer to tap the
rear PTO shaft, 1, into the differential housing.
30000432
132
3. Use snap ring pliers to install the snap ring, 1, that
retains the 39-tooth gear, 2, onto the rear PTO 2
shaft, 3.
1
30000402
133
31-63
NOTE: When installing the fork, 1, onto the PTO
shifter rail, 2, be sure that the fork is placed in the 1 4
groove on the gear coupler, 3.
4. Place the rear PTO fork, 1, onto the PTO shifter

rail, 2, and use a hammer and a suitable punch
to drive in the roll pin, 4, that secures the fork to 2
the rail.
3
30000401
134
NOTE: When installing the gear coupler onto the
PTO countershaft, make sure that the side of the
coupler with the chamfered internal splines faces
rearward in the differential case.
3
5. Place the gear coupler, 2, and the snap ring, 1, 1
onto the PTO countershaft, 3, while installing the
PTO countershaft into the rear of the differential
housing.
2
30000400
135
6. Align the splines on the end of the PTO
countershaft with the PTO clutch splines and
using a hammer and suitable drift, drive the PTO
countershaft, 1, into the PTO clutch and
1
30000407
136
31-64
7. Install the snap ring, 1, that secures the sliding
gear coupler, 2, onto the PTO countershaft, 3.
2
1
30000399
3
137
NOTE: When installing the shifter rail, 3, be sure that
the detents in the rail face up and front in the 1 3
2
NOTE: When installing the mid PTO shifter fork, 2,

onto the mid PTO shifter rail, 3, be sure that the fork
engages the sliding gear coupler, 4.
8. Install the mid PTO shifter rail, 3, into the

differential housing and place the shifter fork, 2,
onto the rail.
4
9. Use a hammer and suitable punch to install the
roll pin, 1, that secures the shifter fork, 2, to the 30000398
shifter rail, 3. 138
housing, 3.
30000356
139
31-65
11. Install a new rear PTO countershaft bearing seal,
1, into the rear differential housing, 2.
1
30000385
140
12. Place a new gasket between the rear differential
housing, 3, and the PTO shaft seal cover, 2, and
install the four bolts, 1, which secure the cover to
the differential. Torque the bolts to bolt torque
13. Assemble the differential and transmission and 1
install onto the tractor. Refer to Section 27, “Rear
Axle”. 2
3
30000385
141
Op. 31 120 00
MID PTO COUNTERSHAFT AND DROP BOX 4 3 2 5
Removal
1. Remove the left and right axle and brake
assemblies from the differential housing. Refer to
Section 27, “Rear Axle”.
2. Remove the differential lock tension spring, 1,
from the fork, 2, and roll pin, 3.
3. Use a hammer and punch to drive the internal roll 1
pin, 3, out of the differential lock rail, 5.
30000408
4. Use a hammer and punch to drive the outer roll
pins, 4, out of the differential lock rail, 5. 142
31-66
5. Remove the differential lock rail, 1, fork, 2, and
differential lock return spring, 3, from the
differential housing. 2
6. Remove the PTO countershaft and rear PTO 3
shaft.
1
30000409
143
WARNING
When removing the rear PTO shifter rail from the
differential housing, the detent ball is under
pressure and could be expelled from the
differential housing with great force. Always
wear eye protection when working.
NOTE: Use a rag to catch the detent ball and spring

when removing shifter rail.
1
7. Remove the rear PTO shifter rail, 1, from the
30000428
144
8. Remove the differential and ring from the
differential housing. Refer to Section 27 “Rear
Axle”.
30000411
145
31-67
9. Remove the seal, 1, for the upper mid PTO
countershaft from the differential housing.
30000410
146
10. Remove the snap ring, 1, which retains the upper
mid PTO countershaft bearing, 2, in the
2
1
30000412
147
11. Remove the front bearing, 1, and the 25-tooth
gear, 2, from the upper mid PTO countershaft, 3.
Slide the mid PTO countershaft, 3, out the rear of
the differential housing.
2 1
30000413
148
31-68
12. Remove the 6 bolts, 1, that secure the mid PTO
drop box, 2, to the differential housing. Remove
the drop box from the housing.
2 1
30000414
149
13. Remove the 7 bolts, 1, that secure the four-wheel
drive drop box, 2, to the differential housing.
Remove the drop box from the housing.
30000415
2
150
14. Remove the seal, 1, for the lower mid PTO
countershaft from the differential housing.
30000416
151
31-69
15. Remove the snap ring, 1, which retains the lower
mid PTO countershaft bearing, 2, in the
2
30000417
152
16. Use a hammer and drift to drive the lower mid
PTO countershaft, 1, out of the differential case.
Remove the collar, 2, 33-tooth gear, 3, and the
rear bearing from the differential housing.
2
1
30000418
153
31-70
10
9
8
6
5
2
4
3
13
12
11
20000419
154
1. Mid PTO Shaft Cover 8. Rear Bearing
2. Locating Pin 9. Snap Ring
3. Oil Seal 10. Bearing Seal
4. Front Bearing 11. Mid PTO Drop Box Housing
5. 31-Tooth Gear 12. Washer
6. Mid PTO Shaft 13. Drain Plug
7. Shaft Collar
Disassembly 4. Remove the rear bearing, 8, from the mid PTO

1. Remove the rear seal cover, 10, from the mid shaft, 6.
PTO drop box housing, 11. 5. Remove the 31-tooth gear, 5, front bearing, 4,
2. Remove the snap ring, 9, which retains the rear and PTO shaft collar, 7, from the drop box
bearing, 8, in the drop box housing. housing, 11.
3. Use a hammer and suitable drift to drive the mid

PTO shaft, 6, out the rear of the PTO drop box.
31-71
6. Remove the front bearing, 1, from the lower mid
PTO countershaft, 2.
2
1
20000420
155
7. Remove the rear bearing, 5, and the 21-tooth
gear, 4, from the upper mid PTO countershaft, 3.
7
6
5
4
3
2
20000421
1
156
1. Front Bearing 5. Rear Bearing
2. 25-Tooth Gear 6. Snap Ring
3. Upper Mid PTO 7. Bearing Cover
Countershaft 8. Differential Housing
4. 21-Tooth Gear
31-72
Inspection
1. Remove and discard oil seal, 1, from the mid
PTO drop box housing, 2. 1
2
2. Remove and discard the O ring on differential
lock rail.
20000419
157
3. Remove and discard the differential lock oil seal,
1, from the differential case.
4. Check detent spring and ball for damage.
air dry.
Replace as needed.
7. Check all gears for chipped or missing teeth. 1
Replace as needed.
turned by hand. 30000433
9. Lubricate bearings in clean hydraulic oil before 158

assembly.
31-73
10
9
8
6
5
2
4
3
13
12
11
20000419
159
1. Mid PTO Shaft Cover 8. Rear Bearing
2. Locating Pin 9. Snap Ring
3. Oil Seal 10. Bearing Seal
4. Front Bearing 11. Mid PTO Drop Box Housing
5. 31-Tooth Gear 12. Washer
6. Mid PTO Shaft 13. Drain Plug
7. Shaft Collar
Assembly 11. Slide the mid PTO shaft through the back of
1. Drive the rear bearing, 8, onto the mid PTO shaft, the drop box housing, 11, through the shaft collar,
6. 7, and through the 31-tooth gear, 5, and into the
front bearing, 4.
2. Drive a new oil seal, 3, into the mid PTO drop box
housing, 11. 4. Using a hammer and drift, drive the mid PTO
shaft, 6, into the drop box housing and front
NOTE: When installing the 31-tooth gear into the bearing.
drop box housing, be sure that the side of the gear
with the groove and lip faces front in the housing. 5. Install the snap ring, 9, into the drop box housing,
11.
3. Place the front bearing, 4, the 31-tooth gear, 5, 6. Install a new bearing seal, 10, into the drop box
and the shaft collar, 7, into the drop box housing, housing, 11.
31-74
Installation
1. Drive the front bearing, 3, onto the lower mid PTO
countershaft, 4.
2. Place the rear bearing, 7, into the differential
housing, 8.
NOTE: When placing the 33-tooth gear into the
differential housing, be sure the side of the gear with 8
the lip is facing to the front of the differential housing.
3. Lower the 33-tooth gear, 5, and the shaft collar,

6, into the differential housing, 8. Place them onto
the mid PTO countershaft, 4, as it is being 7
installed through the front of the differential 6
housing, 8, and into the rear bearing, 7.
5
4
3
2
20000420 1
160
1. Bearing Seal 5. 33-Tooth Gear
2. Snap Ring 6. Shaft Collar
4. Lower Mid PTO 8. Differential Housing
Countershaft
4. Use a hammer and drift to drive the lower mid

PTO countershaft, 1, into the differential housing.
30000429
161
5. Install the snap ring, 1, which retains the front
countershaft bearing, 2, in the differential
housing.
2
30000417
162
31-75
6. Install a new bearing seal, 1, into the differential
housing.
30000416
163
NOTE: When installing the four-wheel drive drop
box, be sure that the arm that engages the 4 wheel
drive is aligned with the engagement fork in the drop
box.
NOTE: When installing the four-wheel drive drop box

and mid PTO drop box onto the differential housing 1
use LocTite Black RTV between the differential
housing and the drop box. Use LocTite Thread
Sealant 567 on the securing bolts.
1
7. Install the four-wheel drive drop box, 2, onto the
differential housing and secure the drop box with 30000415
2
the 7 bolts, 1. Tighten bolts to torque
164
8. Install the mid PTO drop box, 2, onto the

differential housing and secure the drop box with
the six bolts, 1. Tighten the bolts to torque
specifications listed I the back of this section.
2 1
30000414
165
31-76
9. Place the front bearing, 1, for the upper mid PTO
countershaft, 3, inside the differential housing, 8.
10. Place the 21-tooth gear, 4, onto the upper mid
PTO countershaft, 3, and drive the rear bearing,
5, onto the mid PTO shaft, 3.
NOTE: When installing the 25-tooth gear onto the
8
mid PTO countershaft, be sure that the side of the
gear with the lip on it is facing to the front of the
11. While installing the mid PTO countershaft, 3, 7

through the rear of the differential housing, 8, 6
place the 25-tooth gear, 2, onto the countershaft. 5
4
3
2
20000421
1
166
2. 25-Tooth Gear 6. Snap Ring
3. Upper Mid PTO 7. Bearing Cover
Countershaft 8. Differential Housing
4. 21-Tooth Gear
12. Align the upper mid PTO countershaft with the

front bearing and use a hammer and drift to drive
the upper mid PTO countershaft, 1, into the front
bearing and differential housing.
1
30000430
167
13. Install the snap ring, 1, which secures the rear
bearing, 2, for the upper mid PTO countershaft in
the differential housing.
2
1
30000412
168
31-77
14. Install a new bearing seal, 1, for the upper mid
PTO countershaft into the rear of the differential
housing.
30000410
169
15. Install the differential and ring gear into the
differential housing. Refer to Section 27, “Rear
Axle”.
16. Install the rear PTO shaft into the differential
housing.
30000411
170
WARNING
When installing the rear PTO detent ball and
spring into the differential housing, use caution,
as the ball and spring are under significant
pressure and may be expelled with force. Always
wear safety glasses.
NOTE: When installing the rear PTO shifter rail in the

differential housing, be sure that the ball detents in
the rail are facing towards the bottom of the
differential housing and the rear PTO engagement 1
arm, 1, is in the recess on the shifter rail, 2.
30000426
171
31-78
17. Place the detent spring in the differential housing.
Using a detent ball tool, 1, (NH #FNH00081, CIH 1
#CAS2788) install the rear PTO detent ball and
rear PTO shifter rail, 2, into the differential housing. 2
18. Install the PTO countershaft into the differential
housing.
30000427
172
19. Install a new differential lock oil seal, 1, in the
30000433
173
31-79
NOTE: When installing the differential lock fork, 3, be
sure the fork is placed in the groove of the differential
lock clutch, 6. 3
4
20. Install a new O ring, 1, on the differential lock rail,
2. Slide the differential lock fork, 3, onto the rail
as the rail is being inserted into the differential 2
housing. 1
21. Install the differential lock return spring, 4, onto
the differential lock rail, 2, as the rail is being
inserted into the differential housing.
30000409
174
22. Have an assistant compress the differential lock
return spring, 1, to provide access to drive the
internal roll pin, 2, into the differential lock rail, 3.
4 2 6 3
23. Have an assistant push the differential lock rail,
3, into the differential case to provide access to
drive the outer roll pins, 4, into the rail.
24. Install the differential lock tension spring, 5, onto
the roll pin, 2, and differential lock fork, 6.
25. Install the left and right axle assemblies onto the
differential housing. Refer to Section 27, “Rear
Axle”. 1
5
30000408
26. Install the PTO clutch cover and lift cover,
applying LocTite RTV on the sealing surfaces. 175
Tighten nuts and bolts to torque specifications
listed in the back of this section.
27. Install the differential to the transmission and
then install assembly onto tractor. Refer to
Section 27, “Rear Axle”.
31-80
SECTION 33 -- BRAKES -- CHAPTER 1
SECTION 33 - BRAKES
Chapter 1 -- Brakes
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
33 120 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
33 110 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
33 120 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal and Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
33-1
SPECIFICATIONS
Brake Discs
No. of Brake Discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Disc ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 mm (5.6 in.)
Disc OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 mm (6.9 in.)
Total Brake Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8 sq. in.
Total Brake Disc Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 mm (.158 in.)
Standard Lining Groove Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (.008 in.)
Allowable Limit (Minimal Groove Depth) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (.002 in.)
Stators
No. of Stators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Stator Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 mm (.126 in.)
Level Difference-Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1 mm (.004 in.)
Clearance of Pedal Shaft and Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 - 0.35 mm (.002 - .014 in.)
Allowable Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm (.039 in.)
Brake Pedal Free-Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 - 45 mm (1.38 - 1.77 in.)
33-2
Metric Bolt Torque Specifications

4T, 4.8 3.6 -- 5.1 4.9 -- 6.9
M6 7T, 8T, 8.8 1.0 6.1 -- 8.3 8.3 -- 11.3 ------------ ------------ ------------
10T, 11T 8.6 -- 11.6 11.7 -- 15.7
4T, 4.8 9.4 -- 12.3 12.7 -- 16.7 11.2 -- 14.9 15.2 -- 20.2
M8 7T, 8T, 8.8 1.25 16.7 -- 21.0 22.6 -- 28.4 1.0 19.6 -- 25.3 26.5 -- 34.3
10T, 11T 21.0 -- 26.8 28.5 -- 36.3 22.4 -- 29.7 30.4 -- 40.2
4T, 4.8 18.8 -- 24.6 25.5 -- 33.3 21.0 -- 26.8 28.5 -- 36.3
M10 7T, 8T, 8.8 1.5 32.5 -- 41.3 44.1 -- 55.9 1.25 36.2 -- 46.3 49.0 -- 62.8
10T, 11T 39.8 -- 51.3 54.0 -- 69.6 42.7 -- 54.2 57.9 -- 73.5
4T, 4.8 27.5 -- 34.8 37.3 -- 47.1 31.8 -- 40.5 43.1 -- 54.9
M12 7T, 8T, 8.8 1.75 48.5 -- 61.5 65.7 -- 83.3 1.25 54.9 -- 69.4 74.5 -- 94.1
10T, 11T 68 -- 85.6 92 -- 116 73.1 -- 93.7 99 -- 127
4T, 4.8 46.3 -- 59.3 62.8 -- 80.4 51.4 -- 64.4 69.7 -- 87.3
M14 7T, 8T, 8.8 2.0 76.8 -- 97.4 104 -- 132 1.5 85.6 -- 109 116 -- 148
10T, 11T 102.6 -- 129 139 -- 175 110 -- 136 149 -- 185
4T, 4.8 63.5 -- 81.2 86 -- 110 67.2 -- 84.9 91 -- 115
M16 7T, 8T, 8.8 2.0 110 -- 136.5 149 -- 185 1.5 116 -- 142 157 -- 193
10T, 11T 151.3 -- 188 205 -- 255 162 -- 199 220 -- 270
4T, 4.8 83.4 -- 104 113 -- 141 96.7 -- 120 131 -- 163
M18 7T, 8T, 8.8 2.0 145 -- 174 196 -- 236 1.5 169 -- 206 230 -- 280
10T, 11T 203 -- 246 275 -- 333 220 -- 270 299 -- 367
4T, 4.8 106 -- 133 144 -- 180 126 -- 155 171 -- 211
M20 7T, 8T, 8.8 2.5 177 -- 214 240 -- 290 1.5 203 -- 245 275 -- 333
10T, 11T 268 -- 252 363 -- 341 293 -- 358 397 -- 485
33-3
Op. 33 120
BRAKES
The rear axle used on the D35, DX35, D40, DX40,
D45 and DX45, is a double reduction type, consisting
of a conventional ring gear and pinion for primary
reduction, and a final drive pinion and gear for
secondary reduction.
The axle housing, 1, encloses the brake discs and
stators, 2. The rear axle and differential components
are lubricated by the common hydraulic oil reservoir.
The brakes are a mechanically actuated, wet disc 2 1

type. The brakes are located outside of the
differential housing and are enclosed in the front
portion of the axle housing. The brake housing cover
seals the brakes from contaminants and moisture.
20000933
1
The brake discs, 1, are splined to the final drive pinion
shaft, 2, and turn at the same speed as the differential 2
3
assembly. The stators, 3, are kept in position by a
locating pin, 4, in the axle housing.
4
1
20000934
33-4
8
5
6
4
3
7
9
2
20000935
3
NOTE: The brake pedals on the D35, D40 and D45 spring, 6, tension, and forces the rotating brake
tractors are located on the right side of the tractor. discs, 7, and stators, 8, against each other creating
The brake pedals on the DX35, DX40 and DX45 friction to slow the rotation of the axles.
tractors are located on the left side of the tractor.
Operation of the brakes is the same on both model Releasing the brake pedal, 1, allows the pedal return
tractors. spring, 9, to pull the brake lever, 3, back to its original
position, which allows the brakes to release.
Depressing the brake pedal, 1, actuates the brake
rod, 2, which is connected to the brake lever, 3. When the brake lever, 3, returns to its original
position, the brake cam, 4, releases the actuator
The brake lever, 3, is connected to the brake cam, 4, plate, 5, and allows the actuator return springs, 6, to
which rotates against the actuator plate, 5. The release the pressure on the brake discs, 7, and
actuator plate, 5, then overcomes the actuator return stators, 8, allowing the axles to rotate freely.
33-5
Op. 33 110
PARKING BRAKE
A parking brake is provided to hold the brakes in a 1
locked position when the parking brake lever, 1, is
locked. The parking brake lever, 1, holds the pawl, 2,
in a locked position on the inside brake pedal only.
The parking brake lever is located to the left of the

operators seat on the DX35, DX40 and DX45. The
parking brake lever is located on the right side 2
platform on the D35, D40 and D45 tractors.
20002369 D35, D40, D45
20000936 DX35, DX40, DX45
33-6
Op. 33 120
OVERHAUL
BRAKES
Removal and Disassembly
NOTE: The brakes may be serviced with the axle
case attached to the differential housing, but if final
pinion service is required, the axle case must be re-
moved from the differential housing.
1. Disconnect the brake rod clevis, 1, from the
brake arm, 2.
2 1
6
2. Loosen and remove the retaining nut, 1, on the
brake lever, 2. Remove the brake lever, 2, from
the brake cam.
30000177
7
3. Loosen and remove the brake cover retaining
bolts, 1.
1
30000178
33-7
4. Remove the brake cover assembly, 1, from the
differential housing, 2 2
1
30000179
9
5. Remove the three springs, 1, that secure the
brake actuator plate, 2, to the brake cover, 3. 3
2
30000180
10
6. Remove the brake actuator plate, 1, the steel
balls, 2, and the brake cam, 3, from the brake
3 4
cover, 4.
2 2
30000181
11
33-8
7. Remove and discard the brake cam, oil seal, 1,
from the brake cover, 2.
2
30000182
12
8. Remove the stators, 1, and the brake discs, 2,
from the final pinion shaft, 3. 3
2
1
30000183
13
Inspection
NOTE: See “SPECIFICATIONS” for wear values. If
proper measuring equipment is not available, re-
place the brake discs as a set, when the grooves in
the disc lining are no longer visible.

air dry.
2. Inspect the brake discs for excess wear or
damage. Replace the discs if the lining groove is
worn past the replacement limits.
3. Inspect the brake stators for excess wear or
damage. Replace the stators if wear exceeds
specifications.
4. Inspect the brake cam, the steel balls, and the
springs for excessive wear or damage. Replace
as necessary.
5. Inspect the brake cover for damage or cracks.
33-9
Assembly and Installation
1. Install the stators, 1, and the brake discs, 2, onto 3
the final pinion shaft, 3.
2
1
30000183
14
2. Lubricate a new brake cam, oil seal, 1, with
petroleum jelly, and install into the brake cover, 2.
2
30000182
15
3. Install the brake cam, 3, the steel balls, 2, and the
brake actuator plate, 1, into the brake cover, 4. 3 4
2 2
30000181
16
33-10
4. Install the three springs, 1, securing the brake
actuator plate, 2, to the brake cover, 3. 3
2
30000180
17
5. Install the brake cover assembly, 1, onto the
differential housing, 2. 2
30000179
18
6. Install and tighten the brake cover retaining bolts,
1.
1
30000178
19
33-11
7. Install the brake lever, 2, onto the brake cam, and
secure with the retaining nut, 1. Tighten the
retaining nut, 1.
30000177
20
8. Connect the brake rod clevis, 1, to the brake arm,
2.
2 1
21
Adjustment
19 -- 30 mm
1. Measure the brake pedal free travel, 1. (3/4 -- 1-3/16 in.) 1
2. If adjustment is required, loosen the locknut, 2,
on the brake rod, 3. Turn the brake rod, 3, and
remeasure the pedal free travel, 1. When correct
free travel of 19 - 30 mm (3/4 - 1-3/16 in.) is 3
achieved, tighten the locknut, 2.
IMPORTANT: Be sure to test drive the tractor to
make sure the braking action on both rear wheels is
equal. If necessary, adjust the outer brake rod to
equalize the free travel.
2
22
33-12
SECTION 35 -- HYDRAULIC SYSTEM -- CHAPTER 1
Chapter 1 -- Hydraulic System
CONTENT

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flow Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Fluid Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
35 080 Combination System Relief -- Diverter Valve Manifold Assembly . . . . . . . . . . . . . . . . . 10
35 200 Control Valve Assembly (HPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
35 210 Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
35 210 Raising Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
35 210 Lowering Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
35 200 Bypass Spool -- Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Closed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
35 200 Open Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
35 183 Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
35 108 Single Lever -- Position Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
35 108 Neutral Position to Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Raise Position to Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Neutral Position to Lowering Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
35 112 Dual Lever Position Control (Draft Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Top Link Sensing Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Top Link Sensing Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Varying Draft Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
35 124 Combining Position and Draft Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Main System Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Inlet Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
35-1

Overhaul -- Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
35 110 Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
35 200 Hydraulic Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
35 180 Combination System Relief Valve and Diverter Valve Assembly . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
35 182 PTO System Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
35 124 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
HPL Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Description of Operation -- Hydraulic Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
35 304 Hydraulic Pump and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
35 304 Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
35-2

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
35 300 Sump Tube and Screen Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Description of Operation -- Remote Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
35 204 Remote Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Front (Double-Spool) Remote Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Rear (Single-spool) Remote System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Fluid Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Remote Cylinder Extending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Remote Cylinder Retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Front Remote (Two Spool) Loader Control Valve Fluid Flow Diagrams . . . . . . . . . . . . . . . 65
Bucket Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Neutral/Lift Control-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Dumping/Lift Control-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Dumping REGEN/Lift Control-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Roll Back/Lift Control-Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Neutral/Lift Control-Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Neutral/Lift Control-Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Neutral/Lift Control-Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
35 204 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Front (Double Spool) Remote Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
35-3
SPECIFICATIONS
Hydraulic Pump
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gear
Pump Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1 lpm (9.8 gpm)
Pump Speed (rpm):
D35, DX35, D40, DX40, D45, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2600 rpm
Engine Speed (rpm): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2800 rpm
System Relief Valve Setting

D35, DX35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 bar (2275 psi)
D40, DX40, D45, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170 bar (2500 psi)
Lift Cylinder Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm (3.155 in.)
Rear 3-Point Hitch

Maximum Lift Capacity
@ Hitch
D35, DX35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1273 kg (2805 lbs.)
D40, DX40, D45, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1486 kg (3275 lbs.)
@24″
D35, DX35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 920 kg (2025 lbs.)
D40, DX40, D45, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1059 kg (2330 lbs.)
Safety Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245 ± 20 bar (3555 ± 290 psi)
Reservoir Capacity
12x12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 L (9.2 gal.)
HST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 L (9.6 gal.)
Recommended Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hy-Tran Ultra

Cold Weather Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low temp Hy-Tran Ultra
35-4

4T, 4.8 2.8 - 4.0 3.8 - 5.4
M5 7T, 8T, 8.8 0.70 4.9 - 6.9 6.9 - 9.3 ----------- ------------ ------------
10T, 10.9, 11T 6.7 - 9.4 9.0 - 12.7
4T, 4.8 3.6 - 5.1 4.9 - 6.9
M6 7T, 8T, 8.8 1.0 6.1 - 8.3 8.3 - 11.3 ----------- ------------ ------------
10T, 10.9, 11T 8.7 - 11.6 11.8 - 15.7
4T, 4.8 9.4 - 12.3 12.7 - 16.7 11.2 - 14.8 15.2 - 20.1
M8 7T, 8T, 8.8 1.25 16.6 - 21.0 22.6 - 28.4 1.0 19.5 - 25.3 26.5 - 34.3
10T, 10.9, 11T 21.0 - 26.8 28.4 - 36.2 22.4 - 29.7 30.4 - 40.2
4T, 4.8 18.8 - 24.6 25.5 - 33.3 21.0 - 26.8 28.4 - 36.3
M10 7T, 8T, 8.8 1.5 32.5 - 41.2 44.1 - 55.9 1.25 36.2 - 46.3 49.0 - 62.8
10T, 10.9, 11T 39.8 - 51.4 53.9 - 69.9 42.7 - 54.2 57.9 - 73.5
4T, 4.8 27.5 - 34.7 37.3 - 47.1 31.8 - 40.5 43.1 - 54.9
M12 7T, 8T, 8.8 1.75 48.5 - 61.5 65.7 - 83.4 1.25 55.0 - 69.4 74.5 - 94.1
10T, 10.9, 11T 68.0 - 85.4 92.9 - 116 73.1 - 93.3 99.0 - 127
4T, 4.8 46.3 - 59.3 62.8 - 80.4 51.4 - 64.4 69.6 - 87.3
M14 7T, 8T, 8.8 2.0 76.7 - 96.9 104 - 131 1.5 86.1 - 109 117 - 148
10T, 10.9, 11T 102 - 129 139 - 175 108 - 137 147 - 186
4T, 4.8 63.6 - 81.0 83.3 - 110 67.3 - 84.6 91.3 - 115
M16 7T, 8T, 8.8 2.0 110 - 136 149 - 184 1.5 116 - 142 157 - 192
10T, 10.9, 11T 152 - 188 206 - 255 163 - 199 221 - 270
4T, 4.8 106 - 132 144 - 179 127 - 156 172 - 211
M20 7T, 8T, 8.8 2.5 177 - 213 240 - 289 1.5 203 - 246 275 - 333
10T, 10.9, 11T 268 - 325 363 - 441 293 - 358 397 - 485
Flow Control - Cylinder Head Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.7 - 83.4 N⋅m (48.5 - 61.5 ft. lbs.)
Hydraulic Pump Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 - 28 N⋅m (16 - 20 ft. lbs.)
35-5
SPECIAL TOOLS
Description Tool No.
Hose
7/16″ - 20 FJIC SE x Disconnect Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #FNH02106, CIH #CAS2809
Gauge (0 -- 3000 psi) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OEM1462
Lowering Valve Seat Removal Tool

(NH #FNH00357, CIH #CAS2780)
1
Check Valve Seat Removal Tool - Fabricate Using 2
- 3 mm (0.080″ - 0.120″) Dia. Wire
35-6
1
3
2
3 4
20000348
3
Op. 35 000
The hydraulic position control is standard equipment
on all model tractors. The open center hydraulic sys-
tem consists essentially of a fluid reservoir, hydraulic
pump, lift cylinder and piston, control valve and lift
links.
The rear axle and transmission housing serve as a

common hydraulic fluid reservoir and supply fluid to
the hydraulic pump, 1, through the filter, 2, and suc-
tion tubes, 3. The hydraulic pump supplies hydraulic
fluid to the system control valve through the com-
bination relief/diverter valve manifold, 4, and the high
pressure line, 5. The control valve, when operated,
affects raise, neutral, or lowering action of the lift
arms, 6. Hydraulic fluid is returned through line, 7.
The hydraulic pump, 1, is mounted on the right side
of the engine and is driven by the engine oil pump
gear located on the front of the engine block.
10998221
4
35-7
7
13
12
11
10
6
9
4
5
20000439
Hydraulic Flow Diagram/Component Description
1. Hydraulic Fluid Reservoir 8. Rear Single Spool Remote Valve

2. Sump Screen Filter 9. Rear Remote Lift Cylinder
3. Hydraulic Fluid Filter 10. Rear Remote Endcap (Attached to HPL Valve)
4. Hydraulic Pump 11. HPL Valve (Control Valve)
5. Relief/Diverter Valve 12. Flow Valve
6. Front Double Spool Remote Valve 13. 3 Point Hitch Lift Piston
7. Front Boom Lift Cylinder
FLOW PRIORITY
This diagram shows hydraulic oil flow priority within
the tractor’s hydraulic system.
35-8
HYDRAULIC SYSTEM
The hydraulic fluid is pressurized by the hydraulic 1
pump and flows through the PTO system diverter
valve, 1, the combination system relief-diverter
valve, 2, to the control valve. The hydraulic pump and
diverter valves are located on the right side of the
tractor. The control valve is located inside the hy-
draulic lift cover assembly.
2
10998381
6
The hydraulic system is controlled by a series of lev-
ers, 1, 2, 3, 4, and an adjustable stop, 5, for returning 3
the float control lever to a preset position. Another le- 7 4
ver, 6, is for draft control, if equipped. There is an op-
tional remote hydraulic control lever, 7, for D35, D40,
and D45 series tractors.
2
1
5
6
10997819
7
HYDRAULIC FLUID FILTER
The suction filter, 1, is a canister-type filter. The filter
should be replaced after 300 hours of use.
1
8
35-9
Op. 35 080
1 3 2
COMBINATION SYSTEM RELIEF --
DIVERTER VALVE MANIFOLD ASSEMBLY 5 4
The combination system relief-diverter valve man- 7
ifold, 1, is located in the high-pressure line on the right
side of the tractor. The PTO system diverter valve, 2,
is attached to the relief valve. This valve, 2, and the
PTO supply line, 3, supplies 0.8 gpm to the hydraulic
PTO system. A supply line, 11, supplies the pump with
hydraulic fluid from the hydraulic fluid reservoir. A high
pressure line, 4, supplies fluid from the pump to the 6
manifold. The control valve line, 5, supplies the hy- 8 9 10 11
10998381
draulic powered lift valve (control valve). The pressure
relief line, 6, provides a return path back to the reser- 9
voir for hydraulic fluid. The diverter valve spool, 9, nor-
mally provides flow directly to the HPL when the slot
is in the 2 o’clock position.
The diverter valve spool, 9, when rotated to the 10

o’clock position, supplies the auxiliary hydraulics. The
plugs, 7, 8, 10, are removed to connect the auxiliary
pumping. Port, 7, (PB for power beyond) brings flow
pressure back from the front remote. This now sup-
plies the HPL valve or rear remote. Port, 8, (T for tank)
connects the front remote with a path to the reservoir.
Port, 10, (P for pressure) provides pressure out of the
manifold to the front remote valve.
The valve assembly contains the system relief
valve,13, which protects the hydraulic pump from 7 1
overload conditions. The valve body, 1, also serves as
a manifold, containing hose connection ports for use 5 6
2
with auxiliary hydraulic equipment, such as loaders.
The diverter valve spool, 2, permits the operator to se- 6
lect operation of either the auxiliary hydraulic lift sys-
tem circuits or the hydraulic lift system by rotating the
diverter valve spool to the desired position. 7
4 3
8
10 13
11
12
10
1. Valve Body 8. Housing and
2. Diverter Valve Spool Poppet
3. Roll Pin 9. Spring
4. Roll Pin 10. Shim
5. Snap Ring 11. O ring
6. O rings 12. Cap Plug
7. Plug 13. System Relief
Valve Assembly
35-10
The PTO system diverter valve assembly uses a di-
verter spool and spring to supply the PTO system 5 1
with hydraulic fluid at a rate of 0.8 gpm.
2
4 3
6
4
20000435
11
PTO Diverter Valve Parts
1. PTO Diverter Valve Body
2. Diverter Spool
3. Spring
4. O ring
5. Plug
6. Plug
Op. 35 200
CONTROL VALVE ASSEMBLY (HPL)
3 2
The control valve assembly is located inside the hy-
draulic lift cover and contains the control valve spool,
1, bypass spool, 5, check valve, 3, unload valve, 4,
and lowering valve, 2.
12
35-11
7
IMPLEMENT
8
4
3
2
NEUTRAL POSITION - FLUID FLOW
13
Op. 35 210
FLUID FLOW
Neutral Position
In the neutral position, the control valve spool, 1, is pressure on the cylinder side of the check valve, 5.
centered in the valve body. As fluid from the hydraulic This holds it in a closed position. The lowering valve
pump is directed to the valve body, the fluid pressure spool, 6, positioned by the spring, 7, retains the fluid
moves the unload valve, 2, and compresses the in the lift cylinder and maintains the implement in a
spring, 3. This opens the passages, 4, to the sump. fixed position.
Fluid then flows from the pump to these passages
and returns to the sump.
Fluid trapped in the lift cylinder, 8, under weight

caused by the implement on the lift arms, exerts
35-12
5
4
8 6
3
IMPLEMENT
1
7
RAISING POSITION - FLUID FLOW
14
Op. 35 210
Raising Position
When the position control lever is moved to the raise cylinder, 7, to raise the implement. When the fluid
position, the control valve spool, 1, is moved inward pressure exceeds 150 bar (2135 psi), the relief valve,
(rearward). The fluid passages in the control valve 8, opens and fluid is returned to the sump.
are opened, and fluid flows to the check valve, 5,
through the check valve fluid passage, 4. A high pressure safety valve in the lift cylinder head
protects against shock loads by opening at pres-
Fluid pressure against the check valve overcomes sures exceeding 250 ± 20 bar (3625 ± 290 psi), re-
the check valve spring, 6, and the lift cylinder fluid turning fluid to sump.
static pressure on the check valve. This raises the
check valve off its seat, allowing fluid to flow to the lift
35-13
6
2
3
5 4
IMPLEMENT
8
7
1
LOWERING POSITION - FLUID FLOW
15
Op. 35 210
Lowering Position
When the position control lever is moved to the lower- Fluid in the lift cylinder, 7, flows through the passage
ing position, the control valve spool, 1, is moved for- past the check valve, 6, to the lowering valve spool
ward (outward). The plate, 2, and adjusting bolt, 3, at- and seat and returns to the sump, permitting the im-
tached to the control valve spool, also move forward, plement to lower.
making contact with the lowering valve spool, 4, and
pushing it off its seat, 5. The HPL drop rate control valve, 8, can be adjusted
to limit flow returning from lift cylinder to HPL valve.
Fluid from the sump flows through the passages in
the control valve spool and plunger and returns to the
sump in the same manner as in the neutral position.
35-14
Op. 35 200
BYPASS SPOOL - FLUID FLOW
Closed Position B
2 3
The bypass spool and spring are located in the con-
trol valve spool, 1. The purpose of the bypass spool
is to protect the hydraulic system from excessive
pressure. The bypass spool, 3, is held in position (to
the right-hand side of the control valve spool) by a
spring, 2, and the cylinder passage pressure (A),
which is normally higher than the oil pump passage A
pressure (B).
1
16
Op. 35 200
Open Position
When the control lever is moved to the raise position,
fluid flows from the pump and the cylinder passage B
(A) fluid pressure becomes lower than the fluid pres- 2 3
sure at passage (B). The bypass spool operates
(moves to the left-hand side of the control valve
spool) and the bypass circuit is opened, allowing the
remaining fluid to flow to the sump via the bypass
spool, 3.
A
When the cylinder passage pressure (A) and the fluid
pump passage pressure (B) become equal, the by-
pass spool returns to its normal position, and the by- 1
pass passage is closed.
17
35-15
Op. 35 183
FLOW CONTROL VALVE 1 4
2
Fluid flow from the pump enters the lift cylinder
through the check ball, 1, and the flow control valve
needle and seat, 2. When the needle valve is closed
or severely restricted, fluid pressure opens the check
valve and flows to the lift cylinder during the raising
cycle. The one-way check valve prevents fluid from
returning to the lift cylinder, and the lift arms remain
at their set height.
During the lowering cycle, the fluid being exhausted

from the lift cylinder must return to the reservoir via 3
the needle valve and seat. The needle valve control
knob, 3, must be adjusted to obtain the desired rate
of drop.
The high-pressure safety valve, 4, located in the flow

control valve body, protects the lift cylinder against
shock loads. When cylinder pressure exceeds 245 ± 18
20 bar (3555 ± 285 psi), the safety valve opens and
allows the cylinder fluid to escape to the sump.
Op. 35 108
SINGLE LEVER - POSITION CONTROL 1
7
The single-lever hydraulic system uses a single- 6
quadrant control lever, 1, which is connected to the
control valve spool by internal linkage, 2, to maintain
mounted implements at a constant height relative to
the tractor.
When the control lever, 1, is moved, the internal link- 5

age, 2, and control valve spool activate the hydraulic
system, and the lift arms, 7, respond to the move-
ment of the control lever, 1, by either raising, lower-
ing, or remaining in neutral condition. The rod, 6,
which is connected to the lift arm, actuates the feed- 2
back links, 3, 4, and 5, to move the control valve spool
to the neutral position when the desired height is
reached. 3
4
19
35-16
Op. 35 108
1 6 7
Neutral Position To Raise
When the position control lever, 1, is moved to the
raise position, the cam, 2, is rotated between the
cam, 3, and the control valve spool, 8, forcing the 8
control valve inward into a raise position. Pump fluid 5
then flows to the lift cylinder, and the lift arms raise.
2
3 9
4
20
Raise Position To Neutral Position
1 6 7
When the lift arms, 7, raise, the feedback link, 4,
moves rearward allowing the spring-loaded control
valve spool, 8, to move forward (outward) to the neu-
tral position. Pump fluid flow is redirected to the
sump, and the lift arms stop raising.
5
10
2
9
3
8 4
21
Neutral Position To Lowering Position
1 7
When the control lever, 1, is moved to the lowering
position, the cam, 2, is moved upward, reducing the 6
pressure on the control valve spool, 8. The spring, 9,
then moves the control valve spool forward (outward)
and pump fluid flow is directed to the sump. The low- 5
ering arm and screw, 10, moves toward the valve
spool (not shown) pushing it off its seat. This allows 10
the cylinder fluid to exhaust to the sump via the flow 2
control valve and lowers the lift arms.
3 9
8 4
22
35-17
Op. 35 112
Dual Lever Position Control (Draft Control)
The dual lever hydraulic system, if equipped, uses
two levers connected by internal linkage to the con-
trol valve spool. When moved, these levers deter-
mine a raise, lower, or neutral condition for the hy-
draulic system. The 3PT position control lever, 1,
maintains the mounted implement at a selected
height relative to the tractor.
The draft control lever, 2, provides automatic imple- 1

ment depth control to maintain a constant draft on the
tractor. This lever adjusts how sensitive the system 2
10997819
is to ground conditions.
23
The system of automatic depth control (draft control)
use the top compression link to signal for raising or
lowering the implement to maintain a constant draft.
When the position control lever is moved to the full

lowered position, the implement attached to the lift
arms will float until a raise signal is received.
Top Link Sensing Raise

As soil conditions vary, an increase in implement 1
draft will increase the force on the top link, 8. This fur- 7 8
ther compresses the draft control main spring, 7, to
move the feedback linkage, 3, 4, 5, 6, in the direction 6
of the arrows and push the control valve spool, 9, in- 9
ward to a raise position. This action causes the imple-
ment to automatically rise. As the implement is lifted,
the force on the top link, 8, and main spring, 7, de-
creases and reduces the force on the feedback link- 2 5
age and cam, 2, on the control valve spool, 9. The
control valve spring, 10, moves the control valve 3 10
spool, 9, outward into the neutral position when the 4
force on the top link, 8, and main spring, 7, is reduced
to the amount originally selected on the draft control 24
lever, 1. 1. Draft Control Lever
2. Control Lever Cam
3. Feedback Link Cam
4. Feedback Link (Internal)
5. Feedback Arm
6. Adjustment Rod
7. Main Spring
8. Top Link
9. Control Valve Spool
10. Valve Spring
35-18
Top Link Sensing Lower
As the soil conditions vary to decrease the draft load 1
of the implement, the force on the top link, 8, is re- 7 8
duced and causes the main spring, 7, to extend. This
action causes the feedback linkage, 3, 4, 5, 6, to 6
move in the direction of the arrows, reducing the 9
force on the control valve spool, 9. The control valve
spring, 10, then moves the spool, 9, forward into the
lowering position. This action causes the implement
to automatically lower. As the implement lowers, the 2 5
force on the top link, 8, and main spring, 7, increases
the force of the linkage, 3, 4, 5, 6, on the control valve 3 10
spool, 9. The control valve spool, 9, then moves in- 4
ward to the neutral position when the force on the top
link, 8, and main spring, 7, is increased to the amount 25
originally selected on the draft control lever, 1. 1. Draft Control Lever
2. Control Lever Cam
3. Feedback Link Cam
4. Feedback Link (Internal)
5. Feedback Arm
6. Adjustment Rod
7. Main Spring
8. Top Link
10. Valve Spring
Varying Draft Control Settings

1
Varying forces on the top link, 8, move the feedback
linkage, 3, 4, 5, 6, back and forth to apply appropriate 7 8
pressure on the control valve spool, 9 and spring, 10,
6
to maintain a constant draft load on the tractor.
9
The operator manually selects draft load by position-
ing the draft control lever, 1. As the draft lever, 1, is
moved forward (down), the lever cam, 2, is moved up
causing greater top link force to move the feedback 2 5
linkage, 3, 4, 5, 6, and control valve spool, 9, into the
raise position. 3 10
4
As the draft lever, 1, is moved back (up), the lever
cam, 2, is moved down, the control valve spool, 9, is 26
moved closer to the raise position and lifting of the im- 1. Draft Control Lever
plement takes place with a lower increase in top link 2. Control Lever Cam
pressure and less movement of the feedback link- 3. Feedback Link Cam
age. 4. Feedback Link (Internal)
5. Feedback Arm
In summary, adjusting the draft control lever, 1, up or 6. Adjustment Rod
down repositions the lever cam, 2, to provide the ap- 7. Main Spring
propriate resistance on the top link, 8, to suit operat- 8. Top Link
ing conditions. 9. Control Valve Spool
10. Valve Spring
35-19
Op. 35 124
Combining Position And Draft Control Settings
Draft control (implement sensitivity to raising and 7 9
lowering) is adjusted with the draft control lever, 1.
When the ground conditions remain constant, the im- 8
plement depth will also remain constant with the
depth selected by the position control lever, 7. If 10
ground conditions become soft, the top link, 2, and B
B1
main spring, 6, pressure decreases causing the draft 6
control feed back links and the cam, 4, to move the
control valve spool, 5, to lower the implement, 11, 11
1
from position “A” to position “A1”. This is to maintain
the same draft load and top link pressure against the
top of the main spring, 6. 4
A
The position control lever, 7, is used to set a maxi- A1
mum implement operating depth. With the position 5
control lever, 7, set at a maximum depth setting, the 3
lift arms, 8, will lower from position “B” to position “B1” 2
if the ground becomes soft. The lift arms will not lower
27
below position “B1” because the oil in the lift cylinder
1. Draft Control Lever
is retained as the control valve spool, 5, is shifted
2. Top Link
from the lowering to neutral position, thus limiting the
distance the implement, 11, will drop in soft ground. 3. Draft Control Feedback Links
4. Draft Control Feedback Cam
NOTE: If the position control lever fails to lower the
6. Main Spring
implement, the flow control valve is adjusted to the
7. Position Control Lever
closed position or the draft control linkage is in need
8. Lift Arms
of adjustment.
9. Position Control Feedback Links
10. Position Control Feedback Cam
11. Implement
35-20
TROUBLESHOOTING

Implement fails to lift when lever Linkage out of adjustment Adjust external and internal linkage
is in raised position
Relief valve setting too low Perform system relief valve pressure
test
Faulty safety valve Repair or replace safety valve
O ring failure (control valve body Repair as required

to cover, safety valve, relief
valve)
Excessive oil leakage past lift Replace seal, piston, or cylinder as

cylinder piston seal required
Restricted suction filter Replace
Restricted sump screen filter Replace or clean as required
Unload valve does not close Check unload valve operation
Poppet valve remains open Check poppet valve adjustment and

operation
Lift arms cycle up and down Faulty poppet valve and seat Repair or replace as required
when lever is in neutral position
Faulty check valve and seat Replace
Faulty O rings (poppet valve and Inspect and repair as required

seat, valve cover, unload valve
plug)
Poppet valve out of adjustment Adjust to proper clearance

Implement settles too fast when Faulty check valve seat Replace
engine is stopped
Implement rises too slowly Restricted suction filter Replace
Restricted sump screen filter Clean or replace as required
Pump capacity too low Perform flow test and replace pump as
required
Faulty relief valve Repair or replace as required
Excessive leakage past piston Inspect cylinder and piston. Repair as

seal required.
Faulty safety valve Repair or replace as required
Leaking O rings (relief valve, Repair as required

safety valve
Extreme cold weather operation Change hydraulic fluid to Low temp

Hy-Tran Ultra
35-21

Implement will not lower Poppet valve out of adjustment Adjust poppet valve clearance
Flow control valve in closed Open flow control valve

position
Implement does not raise to full Position control rod out of Adjust position control rod
height adjustment
Hydraulic fluid overheats Faulty pump Replace pump
Restricted suction filter Replace
Restricted sump screen filter Clean or replace as required

Relief valve operates when Position control rod out of Adjust position control rod
implement is in full raise position adjustment
35-22
PRESSURE TESTING
MAIN SYSTEM RELIEF VALVE

NOTE: The hydraulic system is equipped with one
system relief valve, located in the combination relief/
diverter valve assembly. This setup gives several op-
tions for checking the system relief pressure. If
equipped, the hydraulic system relief pressure may
be checked using the rear (single spool) remote
valve kit, or a front (double spool) remote valve kit. If
the tractor is not equipped with either of these, the
system relief pressure must be tested using the com-
bination relief/diverter valve.
1. If equipped with a front (double spool) valve kit,
connect a 0 - 207 bar (0 - 3000 psi) pressure 1 2
gauge, 1, to the top high pressure hydraulic line,
2, located on the right side of the tractor. Proceed
to step 4.
20043754
28
2. If equipped with a rear (single spool) valve kit,
connect a 0 - 207 bar (0 - 3000 psi) pressure
gauge, 1, to one of the remote lines, 2, on the rear 2
1
of the tractor. Proceed to step 4.
10008713
29
35-23
3. If the tractor is not equipped with a remote valve
kit, remove the power out (P) manifold plug from
the diverter valve and install a test fitting (3/8 NPT
x 7/16 JIC male). Install a 0 - 207 bar (0 - 3000 psi)
pressure gauge, 1, into the power out port, 2. 1
4. Start the tractor engine and operate the hydraulic

system to warm the hydraulic fluid to normal op-
erating temperature.
5. Set the engine rpm to full throttle (2600 rpm). 2

6. If using the front remote valve, move the valve
control lever to the bucket raise position and ob- 10998803
serve the pressure indication on the gauge.
30
D35, DX35 157 bar (2277 psi)
D40, DX40, D45, 172 bar (2495 psi)
DX45
7. If using the rear remote valve, move the valve le-

ver and observe the pressure indication on the
gauge. If the tractor is a model D35 or DX35, the
indicated pressure should be 157 bar (2275 psi).
If the tractor is a model D40, DX40, D45, or a
DX45, then the pressure reading should be 172
bar (2500 psi).
8. If using the combination relief/diverter valve, set
the diverter valve, 1, from the 10 o’clock position
to the 2 o’clock position, and observe the pres-
sure indication on the gauge, 2.

D35, DX35 157 bar (2277 psi)
D40, DX40, D45, 172 bar (2495 psi)
DX45
1
2
9. If required, adjust the relief pressure setting by
adding or removing shims from the relief valve. 10998803
One shim, 0.3 mm (0.012 in.) thickness, will 31
change the relief pressure setting approximately
10 bar (150 psi).
NOTE: Shim kit SBA340293230 contains three 0.3

mm (0.012 in.) and three 0.1 mm (0.004 in.) shims.
35-24
INLET RESTRICTION
Perform the inlet restriction test to check for the
hydraulic lines and filter for damage, obstructions, or
air leaks. A hydraulic flow meter is required to
perform the inlet restriction test.
WARNING
Leaks of pressurized hydraulic fluid can
penetrate the skin and cause severe injuries.
Tighten all of the connectors before starting the
engine. If hydraulic fluid has penetrated the skin,
seek medical assistance immediately.
NOTE: If equipped with a rear (single-spool) kit,

connect the flow meter to the female quick couplers
in the same manner as described below.
1. Make sure the diverter valve adjuster screw, 1, is
in the 10 o’clock position. 1
2. Remove the manifold plug, 2, from the diverter
valve.
3. Connect a hydraulic line from the “Power Out”
(‘P’) port of the diverter valve to the “Inlet” port of
the flow meter.
4. Remove the manifold plug, 3, from the diverter 2
3
valve.
5. Connect a hydraulic line from the “Tank” port (‘T’)
to the “Return” port of the flow meter. 10012932
32
system to warm the hydraulic fluid to normal
operating temperature.
7. Open the restrictor valve, 1, to allow full flow
through the flow meter.
8. Run the engine at 1400 rpm and record the flow
meter reading.
9. Run the engine at 2800 rpm and read the flow
meter. The reading should indicate that the flow
has doubled. If the meter reading is low, check
the hydraulic lines, and filter for damage, clogs,
or air leaks. If there are no problems with the 1
hydraulic lines or the hydraulic filter, the hydraulic
pump may require replacement. Use the Pump
Efficiency Test described below to further inspect
the hydraulic pump.
50014175
33
35-25
PUMP EFFICIENCY
The Pump Efficiency Test measures the hydraulic
pump output to determine if the pump is excessively
worn or damaged. Perform the Pump Efficiency Test
only after the inlet restriction test has been
completed. A hydraulic flow meter is required to
perform the Pump Efficiency Test.
WARNING
Leaks of pressurized hydraulic fluid can
penetrate the skin and cause severe injuries.
Tighten all of the connectors before starting the
engine. If hydraulic fluid has penetrated the skin,
seek medical assistance immediately.
NOTE: If equipped with a rear (single-spool) kit,

connect the flow meter to the female quick couplers
in the same manner as described below.
1. Make sure the diverter valve adjuster screw, 1, is
in the 10 o’clock position. 1
valve.
3. Connect a hydraulic line from the “Power Out”
(‘P’) port of the diverter valve to the “Inlet” port of
the flow meter.
valve. 2
3
5. Connect a hydraulic line from the “Tank” port (‘T’)
to the “Return” port of the flow meter.
10012932
34
system to warm the hydraulic fluid to normal
operating temperature.
7. Operate the tractor engine at full rpm. Observe
the flow meter reading. The no load reading
should be approximately 34.0 (lpm) / 9 (gpm).
8. Tighten the flow restrictor valve, 1, on the flow
meter until the system pressure is 1900 - 2000
(psi) / 150 (kg/cm2).
9. Observe the flow meter reading, the results
should be approximately 80% of the no--load
flow, minimum rating [27.3 (lpm) / 7.2 (gpm)]. If
testing shows the hydraulic pump output is low, 1
the pump requires replacement.
Hydraulic Systems Pressure Readings

Pump Capacity 37.1 lpm (9.8 gpm)
PTO (1st priority) 3.02 lpm (0.8 gpm)
Pump Flow at Full rpm 34.06 lpm (9.0 gpm) 50014175
Pump Flow Under 80% of No Load 35

Load of 150 kg/cm2 Flow Rating
(1900--2000 psi) 27.3 lpm (7.2 gpm)
35-26
OVERHAUL -- HYDRAULIC SYSTEM
Op. 35 110
6
LIFT CYLINDER
4
NOTE: Tractor wheels have been removed for figure.
Removal 3 5
1. Before removing the lift cover assembly, dis-
charge the fluid from the lift cylinder by lowering 7
the lift links to their lowest position. 8
2. Remove position control rod sway bar, 1, by re-
moving the clevis pin, 2, and removing the bolt, 1
3, that connects the opposite end of the sway bar 2
19998700
to the ROPS. Repeat for the opposite side.
36
3. Disconnect the position control rod assemblies
from the tractor by removing the clevis pin, 4, that
connects the control rod, 5, to the lift arm, 6. Re-
move the bolt, 7, and the retaining pin, 8, which
holds the lower link of the control rod assembly
to the rear axle. Repeat for the opposite side.
4. Disconnect the draw bar, 1, from the lift cover by
removing the clevis pin, 2. 2
5. Remove the left and right fenders.

1
6. Remove the seat.
7. Remove the fuel tank.
8. Remove the Roll Over Protection System (ROPS).
19998700
37
9. On deluxe model tractors, disconnect the link-
age, 1, for the 3-point hitch position control lever
by removing the cotter pin that attaches the link-
age.
3
10. On deluxe model tractors, remove the two bolts,
2, connecting the 3-point position control linkage
bracket, 3, to the right axle housing.
19998695
2 2
38
35-27
11. On economy model tractors, remove the 3-point
position control lever, 1, by using a suitable ham- 2
mer and punch to drive the roll pin, 2, securing
the control lever to the HPL pivot shaft.
1
20000018
39
12. On models equipped with mid PTO, remove the
two bolts, 1, securing the mid PTO safety start
switch bracket, 2, to the differential case and dis-
connect the switch from the wiring harness.
1
19998699
40
1, holding each PTO lever, 2, to the PTO linkage, 2
3.
2 1
14. On deluxe model tractors, remove the cotter
pins, 4, securing the PTO linkage, 3, to mid PTO 4
input shaft, 5, and rear PTO input shaft, 6.
1
4
19998696
5 6
41
35-28
1, securing the PTO linkage, 2, to the lift cover, 3. 3
2 1
19998696
42
16. On deluxe models, separate the flow control
valve linkage, 1, from the lift cover by using a
hammer and suitable punch to remove the roll
pin, 2.
2
1
19998697
43
17. Remove the high pressure line banjo bolt, 1, that
secures the high pressure hydraulic line, 2, to the 3
lift cover, 3. 2
19998701
44
35-29
18. Remove the two bolts, 1, securing the hydraulic
level dipstick tube and dipstick, 2, to the lift cover.
2
19998704
45
19. Remove the 16 nuts and bolts, 1, securing the lift
cover to the differential case.
20. Separate the lift cover from the differential case.
1
1
19998704
46
NOTE: On models equipped with mid PTO, the mid
PTO detent spring, 1, may separate with the lift cover.
Be sure it does not fall into the differential housing.
20000366
47
35-30
21. Using a suitable hoist or lift, remove the lift cover
from the differential housing.
19998702
48
Disassembly
3
1. Remove the pin, 1, and remove the position con- 2
trol rod, 2, from the lift arm, 3. 1
2. Remove the lever grip.
3. Remove the cover bolts, 4, and remove the cover

and valve as an assembly.
4
49
4. Remove the flow control valve attaching bolts
and nuts, 1, and remove the valve and cover as 1
an assembly. 2
NOTE: Cylinder liner may come off with cover and
valve.
50
35-31
5. Remove the cylinder liner, 1, through the front of
the cover assembly.
6. Using a wood dowel, push the piston out of the

liner through the head end.
51
7. Remove the feedback link, from the cross shaft.
8. Remove the snap rings, 1, holding the lift arms,

2, on the cross shaft, 3, from each side.
9. Scribe a mark on the cross shaft, 3, and lift arm,

2, for assembly purposes, and remove the lift
arms using a suitable puller. 2
3
52
10. Scribe a mark on the ram arm, 2, and cross shaft,
1, for assembly purposes.
1
11. Slide the ram arm back on the shaft, 1, while pull-
ing the cross shaft out the left side of the housing.
53
35-32
1. Check the piston and cylinder for excessive wear
or damage. Replace if necessary.
2. Check the cross shaft bushings, 1, for excessive 3 2

wear or damage. Replace the bushings if neces-
sary using a suitable driver, 2. 1
NOTE: Be sure to install the bushings to the correct
depth as shown. 3
2
Bushing depth, 3; D35: 7 mm (0.276 in.)
D40, D45: 8 mm (0.315 in.)
54
Assembly
1. Clean all parts in a suitable solvent and air dry.
1
2. Apply clean hydraulic fluid to all parts, including
O rings and seals, during assembly.
3. Install the cross shaft, 1, in the cover while align-

ing the ram arm, 2, to the scribe marks made dur-
ing disassembly.
55
4. Install the cylinder liner, 1, in the lift cover hous-
ing. Be sure to position the piston rod inside the
liner during installation.
56
35-33
5. Install the O ring, 2, and backup ring, 3, on the
piston, 1, and carefully install the piston in the cyl-
inder.
1
3
2
57
6. Using a new O ring and gasket, install the flow
control valve assembly, 1, and tighten the nuts 2
and bolts, 2, to 65.7 - 83.4 N⋅m (48.5 - 61.5 ft. lbs.).
1
58
NOTE: Be sure to align the reference marks scribed
at time of disassembly. If no scribe marks are pres-
ent, install the lift arms positioned as shown.
48°
24°
59
35-34
7. Using a new O ring, 5, install the bushings, 4,
spring washers, 6, and lift arms, 2, on each side
of the cross shaft, 3. Secure in place with snap
rings, 1.
3 2
4 6
60
Installation
1. Be sure the gasket surfaces of the lift cover and
differential housing are free of old gasket material.
2. If the tractor is equipped with a mid PTO, install

the detent spring in the differential housing.
3. Apply a 0.125 inch bead of LocTite Black RTV Sil-

icone to the surface of the differential housing
that the lift cover assembly mounts to.
1
20000366
61
NOTE: On tractors equipped with a mid PTO, make
sure that the mid PTO tang engages the mid PTO
shifter arm in the differential housing when installing
the lift cover.
4. Using a suitable hoist or lift, install the lift cover

5. Replace the cover nuts and bolts and tighten to

torque specifications listed in the back of this sec-
tion.
6. Install the dipstick tube and dipstick to the lift cov-

er. 19998702
62
7. Using new O rings, install the high pressure line
and banjo bolt onto the lift cover.
35-35
8. On deluxe model tractors, align the flow control
valve linkage, 1, to the flow control valve on the
lift cover and install the roll pin, 2, to secure the
linkage.
9. On deluxe model tractors, install the mid PTO

safety start switch onto the differential case. Con-
nect the switch to the wiring harness.
2
10. On deluxe model tractors, bolt the PTO linkage
to the lift cover. 1
19998697
63
11. On deluxe model tractors, attach the PTO link-
age, 3, onto the PTO input shafts, 5, 6, and se- 2
cure the linkage with cotter pins, 4.
2 1
12. On deluxe model tractors, use bolts, 1, to secure
the PTO levers, 2, onto the PTO linkage, 3. 4
13. On economy model tractors, align the 3-point 1
position control lever onto the HPL pivot shaft
and install the roll pin to secure the lever.
3
4
19998696 5 6
64
14. On deluxe model tractors, secure the 3-point
position control lever bracket, 3, to the right axle
housing and HPL pivot shaft linkage using retain-
ing bolts, 2.
3
15. On deluxe model tractors, attach the 3-point
position control lever linkage, 1, to the HPL pivot
shaft linkage and secure the linkage with a cotter
pin.
16. Install the Roll Over Protection System (ROPS), 1

the fuel tank, the seat, and the left and right fend-
ers.
19998695
2 2
17. Install the position control rod assemblies and
position control rod sway bars. 65
35-36
FLOW CONTROL VALVE

14
Removal
1. Remove the cylinder head retaining bolts and
nut, 17.
13
15
2. Carefully remove the cylinder head assembly. 16
Disassembly
17 10
1. Remove the safety valve guide bolt, 1, and the 8
shims, 3, sealing washer, 2, spring, 4, and ball, 6
5.
2
12
NOTE: Observe the quantity of shims, 3, used be- 1
tween the spring and guide bolt. 11 9
2. Remove the check valve body, 6, seal, 7, O ring, 7 5
8, spring, 9, ball, 10, guide, 11, and gasket, 12.
4 3
3. Remove the flow control valve knob, 16, and nut,
15, and then screw the valve stem, 13, out of the 66
body, 14.
Inspection
1. Wash the components in a suitable solution and
air dry.
2. Inspect the valve seat for excess wear or dam-

age.
3. Inspect the flow control valve stem (seat) and the

two balls for excess wear or damage.
4. Inspect the springs for excess wear or chipping.
Assembly
1. During assembly, apply clean hydraulic fluid to all
components.
2. Screw the valve stem, 13, into the body, 14.
3. Install the nut, 15, and valve knob, 16, on the

guide.
4. Using new O ring, 8, seal, 7, and gasket, 12,

install the guide, 11, ball, 10, spring, 9, and check
valve body, 6.
5. Install the ball, 5, spring, 4, sealing washer, 2,

and valve guide bolt, 1, using the same amount
of shims, 3, removed during disassembly.
Installation
1. Install cylinder head assembly.
2. Install the cylinder head retaining bolts and nut, 17.
35-37
Op. 35 200
HYDRAULIC CONTROL VALVE
Removal
See “Lift Cylinder Removal”, discussed earlier in this
section.
Disassembly
1. Remove the valve to cover-retaining bolts, 1, and
remove the valve, 2, from the cover. 2
1
67
2. Remove the cotter pin, 1, washer, 2, and pin, 3,
from the control valve spool.
1 9 10
3. Loosen the bolt, 4, and remove cap, 5, and
spring, 6, from the control valve body, 7. 2 8
4. Remove the control valve spool, 8, from the valve 4
body, 7. 5
NOTE: Do not remove the adjusting screw, 9, nut, 10, 6
plate, 11, bolt, bypass spool, and spring from the con- 11
trol valve spool, 8, unless required, as this affects the
3
valve adjustment setting.
7
68
5. Using special tool (NH #FNH00357, CIH
#CAS2809), remove the lowering valve seat, 5,
4
with O rings, 4, spring seat, 3, spring, 2, and low-
ering valve spool, 1, from the valve body.
4
1 5
2
3
69
35-38
6. Remove the check valve plug, 1, with O ring, 2,
spring, 3, check valve, 4, and seat, 5, with O ring,
9, from the valve body.
7. Remove the plug, 6, with O ring, 7, spring, 8, and

1
unload valve, 10, from the valve body. 2
3
5 4
9
7 6
10
8
70
Inspection
1. Clean all components in a suitable solvent and
air dry.
2. Inspect the valve spool and bore for excessive

wear, scratches, or other damage.
NOTE: The control valve assembly and the body

must be replaced as a matched set only.
3. Inspect the check valve seat and bushing seat

area for uneven wear or other damage. Replace
the valve and bushing as a set if required.
4. Inspect the unload valve and valve seat area for

uneven wear or damage. Replace the valve and
valve seat as a set if required.
5. Inspect the shutoff valve and valve seat area for

uneven wear or damage. Replace the valve and
valve seat as a set if required.
6. Inspect all O ring grooves for nicks or burrs.
Assembly
1. Apply clean hydraulic fluid to all components, in-
cluding O rings and seals, during assembly.
2. Replace all O rings, gaskets, and seals using 1

new parts. 2
3
3. Install the unload valve, 10, spring, 8, and plug, 5 4
6, with O ring, 7, in the valve body. Tighten the 9
plug to 98 - 117.6 N⋅m (72.33 - 86.8 ft. lbs.). 7 6
4. Install seat, 5, with O ring, 9, check valve, 4,
spring, 3, and plug, 1, with O ring, 2, in the valve 10
body. Tighten the plug to 58 - 58.8 N⋅m (43.4 - 8
50.0 ft. lbs.). 71
35-39
5. Install the spring seat, 3, spring, 2, lowering valve
spool, 1, and lowering valve seat, 5, with O rings, 4
4, in the valve body. Tighten the lowering valve
seat to 29.4 N⋅m (21.7 ft. lbs.).
4
1 5
3 2
72
6. After torquing the lowering valve seat, stake the
seat into position using a center punch. STAKE
VALVE
SEAT
73
7. If removed, assemble the bolt, 1, plate, 2, bypass
spool, 3, spring, 4, nut, 5, and screw, 6, as fol- 5
1
lows:
6
Remove the oil from the threads of the bolt, 1,
and valve spool, 7, and apply thread sealant to
them.
Insert the spring, 4, and bypass spool, 3, into the
valve spool, 7.
2
3
4
7
74
35-40
Install the plate, 2, in position 60_ from the pin
1.3 mm (0.051″)
center and tighten the bolts, 1, to 10 - 15 N⋅m (7.4
- 11 ft. lbs.). 6
Install the screw, 6, until it projects 1.3 mm
(0.05″) from the plate, 2, and tighten the nut, 5, PIN
to 18 - 22 N⋅m (13 - 15 ft. lbs.) torque. 60°
2 CENTER
5
3
4 1 4
PIN HOLE
75
8. Install the control valve spool, 8, into the valve
body, 7.
9 10
9. Install spring, 6, cap, 5, and secure with bolts, 4.
Tighten the bolts to 7 - 10 N⋅m (5.4 - 7.3 ft. lbs.). 1 8
2
10. Install pin, 3, through the control valve and se- 4
cure in place with washer, 2, and split pin, 1. 5
6
11
3
7
76
Installation
1. Using new O rings, install the control valve to the
cover.
2. Install the handles to the cover.
3. Position the control valve and cover assembly

with a new gasket on the lift cover assembly and
install the attaching bolts. Tighten the attaching
bolts to the specified torque. See “Specifica-
4. Install the guides and handle grips.
5. Install the position control link and adjust as de-

scribed later in this section.
35-41
Op. 35 180
5
COMBINATION SYSTEM RELIEF VALVE
AND DIVERTER VALVE ASSEMBLY 3
Removal 4

line, 2, and the pressure line, 3, to the control 2
valve at the valve assembly. 1
10998381
3. Remove the PTO system pressure line, 4, at the
PTO diverter valve body fitting, 5. 77

10996435
78
Disassembly
2
10998804
79
35-42
NOTE: When removing the relief valve plug, make
note of the quantity of shims, 10, if used, between the 7 1
spring, 9, and plug, 12. Retain the shims for use dur-
ing assembly. 5 6
2
6
NOTE: One shim, 0.3 mm (0.012 in.) thickness, will
change the pressure setting approximately 10 bar
(150 psi).
7
2. Remove the relief valve plug, 12, with the O ring, 4 3
11. 8
3. Remove the snap ring, 5, from the diverter valve 9

spool, 2, and withdraw the spool from the valve
body, 1. 10 13
11
Inspection
1. Inspect the relief valve seat and guide for excess 12
wear or score marks.
80
2. Inspect the diverter valve spool and valve body 1. Valve Body 8. Housing and
for excess wear or score marks. 2. Diverter Valve Spool Poppet
3. Roll Pin 9. Spring
3. Inspect the spring for wear or damage. 10. Shim
4. Roll Pin
4. Replace the relief/diverter valve as an assembly 5. Snap Ring 11. O ring
if found to be damaged. 6. O rings 12. Cap Plug
7. Plug 13. System Relief
Valve Assembly
Assembly
1. Using new O rings, 6, install the diverter valve
spool, 2, into the valve body, 1, and install snap
ring, 5.
2. Install the relief valve assembly, 13, with a new O

ring, 11, into the valve body, 1. Be sure to use the
correct number of shims, if necessary, when
installing the relief valve assembly.
3. Using a new O ring, 4, between the PTO valve
body, 1, and the diverter valve body, 2, secure the 2
valves together using the three bolts, 1. 1 3
4
3
10998805
81
35-43
Installation
2. Install the bolt, 1, which secures the combination

system to the tractor. Do not tighten bolt at this
time.
10996435
82
sump return line, 1. Do not tighten fittings at this 5
time.
3
4. Install the bolts and nut securing the pump pres-
sure line, 2, and the pressure line, 3, to control 4
valve to the valve assembly.
5. Tighten all loose bolts and fittings at this time.
2
1
10998381
83
35-44
Op. 35 182
5
PTO SYSTEM DIVERTER VALVE
3
Removal
4

line, 2, and the control valve pressure line, 3, at
the valve assembly. 2
3. Remove the PTO system hydraulic line, 4, at the
1
PTO diverter valve body fitting, 5. 10998381
84
10996435
85
Disassembly
2
10998804
86
35-45
2. Remove the diverter valve plugs, 5, 6, with the
O rings, 4. 5 1
3. Remove the diverter spool, 2, and spring, 3, from
the valve body, 1.
2
Inspection 4 3
6
1. Clean and inspect the diverter valve spool and
valve body bore for excess wear or score marks.
2. Inspect the spring for wear or damage.
3. Replace the PTO diverter valve as an assembly 4

20000435
if found to be damaged.
87
PTO Diverter Valve Parts
Assembly 1. PTO Diverter Valve Body
1. Using a new O ring, 4, install plug, 5, in one end 2. Diverter Spool
of the valve body, 1. 3. Spring
4. O ring
2. Install the spool, 2, and spring, 3, into the valve 5. Plug
body. 6. Plug
3. Using a new O ring, 4, install plug, 6, into the
open end of the diverter valve.
4. Using a new O ring, 4, between the PTO diverter

valve body, 1, and the diverter/relief valve body, 2
2, secure the valves together using the three 1 3
bolts, 3. 4
3
10998805
88
35-46
Installation
2. Install the bolt, 1, which secures the valve as-

sembly to the tractor. Do not tighten the bolt at
this time.
10996435
89
sump return line, 1. Do not tighten fittings at this 5
time.
3
4. Install the bolts and nut securing the pump pres-
sure line, 2, and the control valve pressure line, 4
3, to the valve assembly.
5. Tighten all loose bolts and fittings to torque speci-

fications listed in the back of this section.
2
1
10998381
90
35-47
Op. 35 124
ADJUSTMENTS
HPL LINKAGE
The length of the position control rod is critical and
careful adjustment must be observed for proper op-
eration. If the control rod is adjusted too short, the
control valve spool will remain in the raised position
when the lift arms have reached their maximum
height and the system relief valve will blow. If the con-
trol rod is too long, the control valve spool will return
to neutral before the lift arms reach their full height.
The position control rod should be adjusted any time
the link is disconnected for service to the hydraulic
system, or any time the relief valve operation is no-
ticed while the lift arms are at the full raise position.
Adjustment Procedure
1. Loosen the locknut, 1, on the position control rod,
2, and remove the pin, 3, from the link. 5
2. Set the control lever, 4, to the highest position,
but not in the notch of the upper stop. 3 2 1
3. Start the engine. The lift arms, 5, should raise
and the relief valve should operate.
4. Move the control lever down until the relief valve
ceases operation. 4
5. Adjust the length of the position control rod and
clevis to align the pin holes. Then lengthen the
rod one additional turn and install the pin. Tighten 91
the locknut.
6. Check the operation. The relief valve should not
operate when the lift arms are in the fully raised
position.
CONTROL LEVER
3
Adjustment Procedure 2
The control lever, 1, should not move from vibration.
If adjustment is required, remove the cotter pin, 2,
and adjust the nut, 3, to obtain 2 - 3 kg (4 - 7 lbs.) of
pull at the lever knob.
92
35-48
DESCRIPTION OF OPERATION -- HYDRAULIC PUMP AND FILTER

Op. 35 304
HYDRAULIC PUMP AND FILTER
The hydraulic pump, 1, is mounted on the right side
of the engine and is driven by the engine oil pump
gear mounted on the front of the engine block.
1
The hydraulic pump is a gear type pump and, with ex-
ception of replacing the seals, is not user service-
able.
10998221
93
A screen-type sump filter is housed inside the rear
differential case and is accessed by draining the hy-
draulic fluid from the differential case and removing
the sump screen tube, 1, from the right side of the dif-
ferential housing.
A larger mesh screen covers the sump screen filter

and prevents larger debris from damaging the small-
er filter. This larger mesh screen is removed only by
removing the differential ring and pinion. It may be
accessed for cleaning by draining the hydraulic fluid
and removing the lift cover. 1
10998706
94
A suction type filter, 1, is located in the inlet line on the
right side of the tractor, near the rear axle differential
case. The filter is serviced by replacing the complete
canister assembly. The filter should be replaced after
the first 50 hours of use and every 300 hours of use
thereafter.
95
35-49
Op. 35 304
HYDRAULIC PUMP
The only parts serviced on the hydraulic pump are
the shaft seal and internal O rings. If troubleshooting
indicates a faulty pump, replace the pump with a new
assembly.
Pump Flow lpm (gpm)

D35, DX35, D40, 37.1 (9.8)
DX40, D45, DX45
Removal
1. Remove the two suction tube bolts, 1, from the
1
pump, 2.
2. Remove the four high pressure tube bolts, 3,

from the pump, 2.
3
10998221
96
3. Loosen the hose clamp, 1, on the opposite end
of the suction tube, 2. This is to allow the suction
tube to be rotated out of the way for pump remov-
al.
1 2
10998381
97
4. Remove the four pump mounting bolts and nuts,
3, securing the pump, 1, to the mounting flange,
2.
1
2
10000353
98
35-50
5. Remove the banjo bolt, 1 securing the oil line, 2,
to the engine block.
2
10000344
99
6. Carefully pull the suction tube, 3, out of the way
while removing the pump, 1, from the front 1
mounting flange, 2.
3
10000349
2
100
35-51
13
12
8
3 7
11
10
9
2
5
6
14
1
30000423
101
Disassembly 9. Using a brass drift and hammer, tap the rear of
1. Scribe lines in the pump body, 1, and end covers, the pump driveshaft, 11, and remove the drive
2 and 3, for ease of assembly. shaft from the pump body.
2. Remove the four bolts, 4, that secure the covers, 10. Using a brass drift and hammer, tap the rear of
2 and 3, to the body. the pump gear, 13, and remove the pump gear
from the pump body, 1.
3. Remove the rear cover, 2, from the pump body,
1. 11. Using a brass drift and hammer, remove the rear
wear blocks, 14, noting the orientation of each,
4. Remove the rubber seal ring, 5, and the back up for ease of assembly.
ring, 6.
5. Remove the front cover, 3, from the pump body, Inspection and Repair
1. 1. Wash all parts in clean solvent and air dry.
6. Remove the rubber seal ring, 7, and the back up 2. Discard all seals and back up rings.
ring, 8.
3. Inspect the gears, wear blocks, and pump bore
7. Using snap ring pliers, remove the snap ring, 9. for excess wear and scoring. If necessary, re-
place the pump.
8. Remove the shaft seal, 10, from the front cover,
3.
NOTE: The front wear blocks, 12, will come out with
the drive shaft, 11. Be sure to note the location of
each wear block, as they are each different.
35-52
13
12
8
3 7
11
10
9
2
5
6
14
1
30000423
102
Assembly 7. Install the snap ring, 9, into the end of the front
1. Lubricate all parts during assembly with clean hy- cover, 3.
draulic fluid.
8. Install new back up rings, 6, 8, and seal rings, 5,
2. Place the rear wear blocks, 14, into the pump 7.
body, 1. Be sure that the blocks are oriented cor-
9. Carefully place the front cover, 3, and the rear
rectly.
cover, 2, onto the pump body, 1, aligning the
3. Install the pump gear, 13, into the pump body, 1. scribe marks made previously during disassem-
bly.
4. Install the driveshaft, 11, in to the pump body, 1.
10. Secure the covers, 2, 3, to the pump body, 1, with
5. Place the front wear blocks, 12, into the pump the four bolts, 4. Torque the bolts to 22 - 28 N⋅m
body, 1. Again, be sure that the blocks are ori- (16 - 20 ft. lbs.).
ented correctly.
6. Using a seal driver, install a new shaft seal, 10,

into the front cover, 3.
35-53
Installation
1. Scrape any remaining O ring sealant material
from the pump mounting flange, 1. Apply a small
amount of silicone sealer to the pump mounting
flange.
10000345
103
2. Install a new O ring, 1, on the front cover of the
hydraulic pump.
10000351
104
3. Carefully install the pump, 1, onto the pump
mounting flange, 2, and secure it with the four
nuts and bolts.
1 2
10000352
105
35-54
4. Install the banjo bolt, 1, which secures the oil line,
2, to the engine block.
2
10000344
106
5. Use a new O ring between the pump and the hy-
draulic tube and install the four bolts, 3, that se- 1
cure the high pressure tube to the pump, 2.
6. Use a new O ring between the pump and the hy-

draulic tube and install the two bolts, 1, that se-
cure the suction tube to the pump, 2.
2
3
10998221
107
7. Tighten the hose clamp, 1, on the opposite end
of the suction tube, 2.
8. Tighten all nuts and bolts to torque specifications

listed later in this section.
1 2
10998381
108
35-55
SUMP TUBE AND SCREEN FILTER

2
4
35 300
Removal 1
1. Drain the hydraulic fluid from the differential case
into a suitable container.
2. Remove the two clamping bolts, 1, and clamp, 2,

securing the sump hydraulic line, 3, to the filter 3
housing, 4.
10998705
109
3. Remove the two bolts, 1, securing the opposite
end of the sump hydraulic line, 2, to the differen-
tial case. Remove the hydraulic line.
1 1
2
10998706
110
4. Remove the remaining two bolts, 1, holding the
sump in the differential case and pull the sump
tube and screen filter out of the differential case.
1
1
10998709
111
35-56
Disassembly
1. Separate the sump tube, 1, and metal filter, 2,
2
from each other.
2. Remove and discard all O rings and gaskets.

1
Inspection
1. Visually inspect the filter for damage and/or ex-
cessive debris. Replace or clean with appropri-
ate solvent as necessary.
2. If the screen filter is being reused, be sure that

the filter is clean and dry before assembly. 10998710
112
Assembly
1. Install a new O ring in the O ring groove, 1, inside
the metal filter. 2
2. Install the filter, 2, onto sump tube, 3.

3
10998710
113
3. Replace the sump tube gasket, 1, which goes be-
tween the sump tube and the differential housing.
10000347
114
35-57
4. Place the sump tube and filter back into the differ-
ential case and install the two short bolts, 1,
through the sump tube, 2, and into differential
housing, 3, finger tight. 1
2
3
1
10998709
115
5. Install the sump hydraulic line, 3, back into the
hydraulic filter housing, 4, and thread the two 2
bolts, 1, through the clamp, 2, into the filter hous- 4
ing finger tight.
1
10998705
116
6. Install the sump hydraulic line, 1, back onto the
sump tube, 2, and differential housing using the
two long bolts, 3, to secure the line to the sump
tube.
1
7. Torque all bolts to specifications listed later in this
section.
3
3
2
10998706
117
35-58
DESCRIPTION OF OPERATION -- REMOTE VALVES

Op. 35 204
REMOTE VALVES
Single-spool (rear) and double-spool (front) remote
control valves are available as dealer accessories.
The single-spool remote control valve is mounted on
the outside of the main control valve cover plate on
the right-hand side of the hydraulic lift cover. This op-
tion is available with up to three valves on models
DX35, DX40 and DX45 and a maximum of two valves
on models D35, D40 and D45, available as Kit #1, Kit
#2, and Kit #3. Installation of two valve kits, 1, is
shown.
118
The double-spool remote control valve, 1, is
mounted on the right fender.
119
35-59
REAR (SINGLE-SPOOL) REMOTE VALVE

The rear remote valves are equipped with self-cen- 2
tering springs so that the spools automatically return 6
to neutral when the control handle is released follow- 13
ing a raise or lowering operation. 12
14
9
8
5
3 3 7
1
4 7 10
11
120
1. Valve Body 8. Endcap
2. Valve Spool 9. Bolt
3. Spring Seat 10. Clevis
4. Spring 11. Bolt
5. Bolt 12. O ring
6. O ring 13. Seal Washer
7. Retainer 14. Washer
FRONT (DOUBLE-SPOOL) REMOTE VALVE

(Figure 121)
The double-spool remote valve also contains a
spring-loaded detent mechanism to provide a float
position for loader operation. In float position, fluid is
free to flow between piston and rod sides of the load-
er lift cylinder allowing the lift arms to float over un-
even terrain.
The double-spool remote control valve contains
check valves located in the valve spool passages.
The check valves function to hold the loader lift and
bucket cylinders in a fixed position while the valve is
being initially operated to prevent dropping the load.
In operation, the check valve is retained on its seat
by spring force plus the back side pressure of fluid
contained in the loader cylinder. During initial spool
movement, pump-pressurized fluid fills the passage
to the check valve, and the remaining pump fluid
flows to the sump through the open center passage.
With continued spool movement, the open center
passage closes. Pump pressure increases on the
force of the check valve, overcoming the backside
pressure, and causes the check valve to open. Pump
fluid flow then flows to the cylinder. This action pre-
vents any backflow out of the cylinder and provides
a smooth-lifting action of the loader.
NOTE: Separate installation instructions are pro-

vided for the different remote valve kits.
35-60
34 32
33
28
27 30
31
26
29 2 1
23 25 26
24
3 6
5
25 7
22 8
17 9
10 14
11 15
36
12
18
13
19 35
16 6
20 8 7
37
38
9 1
10
11
12
38
16 2
35
21 4
20000437 39 13 5
121
1. Cap Screws 11. Spring 21. Plug 31. E Clip
2. End Cap 12. Stop Cup 22. Cap Screw 32. Roll Pin
3. Float Detent Sleeve 13. Spacer 23. Joystick Flange 33. Lockout Pin
4. REGEN Detent Sleeve 14. Float Spool 24. Rod End 34. Knob
5. Retainer 15. REGEN Spool 25. Rod End Assemblies 35. Plug
6. Poppet 16. O ring 26. Nuts 36. Plug
7. Detent Spring 17. Check Plug 27. Cap Screw 37. O ring
8. Detent Balls 18. O ring 28. Clevis 38. O ring
9. Detent Retainer 19. Spring 29. Spool Stud 39. O ring
10. Washer 20. Loads Check Poppet 30. Spring
35-61
6 5
7
3
10
1 2
FLUID FLOW NEUTRAL POSITION
122
1. Remote Cylinder 6. HPL Control Valve
2. Implement Load 7. Relief/Diverter Block Manifold
3. Remote Valve Spool 8. Pump
4. Lift Cover End Cap 9. Filter
5. Lift Cover Assembly 10. Reservoir
REAR (SINGLE-SPOOL) REMOTE SYSTEM position, the remote valve spool, 3, directs the pump
fluid flow back through the three-point hydraulic sys-
FLUID FLOW tem to the sump.
Neutral Position
Fluid contained in the remote cylinder, 1, is blocked
With the control valve in the neutral position, fluid by the control valve spool, 3, and the implement, 2,
flows from the pump, 8, past the system relief valve, is held in a fixed position.
7, through the main control valve, 6, and lift valve cov-
er, 5, and into the remote control valve. In the neutral
35-62
6 5
7
3
11
10
12
9
1 2
FLUID FLOW - REMOTE CYLINDER EXTENDING
123
1. Remote Cylinder 7. Relief/Diverter Block Manifold
2. Implement Load 8. Pump
3. Remote Valve Spool 9. Filter
4. Lift Cover End Cap 10. Return Passage
5. Lift Cover Assembly 11. Supply Passage
6. HPL Control Valve 12. Reservoir
Remote Cylinder Extending cylinder returns to the sump through the return pas-
When the remote control valve lever is pushed for- sage, 10.
ward, the valve spool is moved outward to extend the
cylinder. Fluid flow to the three-point hydraulic system is
blocked by the spool during this operation.
Fluid flows from the pump, 8, past the system relief
valve, 7, through the main control valve, 6, and lift If the fluid pressure exceeds 147 ± 5 bar (2130 ± 70
valve cover, 5, to the remote control valve. The con- psi), the main relief valve, 7, opens, and the fluid re-
trol valve spool, 3, now directs the fluid flow through turns to the sump.
passage, 11, to the piston side of the remote cylinder,
1, and extends the cylinder. Fluid in the rod side of the
35-63
6 5
7
3
11 10
12
9
1 2
FLUID FLOW - REMOTE CYLINDER RETRACTING
124
1. Remote Cylinder 7. Relief/Diverter Block Manifold
2. Implement Load 8. Pump
3. Remote Valve Spool 9. Filter
4. Lift Cover End Cap 10. Return Passage
5. Lift Cover Assembly 11. Supply Passage
6. HPL Control Valve 12. Reservoir
Remote Cylinder Retracting der. Fluid in the piston side of the cylinder returns to
When the remote control valve lever is pulled rear- the sump through passage, 11, and internal pas-
ward, the control valve spool, 3, is moved inward to sages in the remote and main control valve and per-
retract the remote cylinder, 1. Fluid then flows from mits the cylinder to retract.
the pump, 8, past the system relief valve, 7, through
the main control valve, 6, and lift valve cover, 5, to the Whenever the remote cylinder pressure exceeds
remote control valve. The control valve spool, 3, now 147 ± 5 bar (2130 ± 70 psi), the main relief valve
directs the fluid flow through passage, 10, to the rod opens, and the fluid returns to the sump.
side of the remote cylinder, 1, and retracts the cylin-
35-64
FRONT REMOTE (TWO SPOOL) LOADER CONTROL VALVE FLUID FLOW DIAGRAMS
8
6
7
3
50035589
125
BUCKET CONTROL body remain closed. Fluid contained in the bucket
control cylinders, 6, and lift control cylinders, 8, is
Neutral/Lift Control-Neutral trapped by the spools, keeping the cylinders in a fixed
When the control lever, 5, is in the neutral position, position.
both control spools, 1 and 2, are centered in the valve
body. Fluid is suctioned from the hydraulic reservoir, When both spools are in the neutral position, the
7, by the hydraulic pump, 3, and is directed through passages to the power beyond (PB) port are open
the relief/diverter manifold, through port “P”, to the and hydraulic fluid flows through the valve body to the
center of the two control spools. In this position, the relief/diverter manifold, 4, and then to the main
spool lands block the work passages to the loader hydraulic control valve. If the hydraulic fluid is not
cylinders. Since there is no hydraulic fluid flowing used by the main hydraulic system, it is returned to
through either spool, both check valves in the valve the hydraulic reservoir, 7.
35-65
8
6
7
3
50035591
126
Dumping/Lift Control-Neutral through passage “B1”, and exits the valve body
When the control lever, 5, is moved to the dumping through the tank port, “T”. Hydraulic fluid is then
position, the bucket control spool, 2, is moved returned to the hydraulic fluid reservoir, 7, through
inward. Fluid flow from the hydraulic pump, 3, is the relief/diverter valve manifold, 4.
directed into the valve body, opening check valve #1,
to passage “A1”. Hydraulic fluid contained on the rod Since the lift control spool, 1, remains in neutral, the
side of the bucket cylinder flows out of the cylinder, lift control cylinders, 8, remain in a fixed position.
35-66
8
6
7
3
50035590
127
Dumping REGEN/Lift Control-Neutral with the hydraulic pump flow and directed to the
When the control lever, 5, is moved to the REGEN piston side of the bucket cylinder. This allows faster
position, the bucket control spool, 2, is moved bucket tipping action and prevents hydraulic fluid
completely inward. Fluid flow from the hydraulic cavitation caused by heavier loads.
pump, 3, is directed to the bucket control spool
through check valve #1, and to passage “A1”. Since the lift control spool, 1, remains in neutral, the
Hydraulic fluid is then directed to the piston side of lift control cylinders, 8, remain in a fixed position.
the bucket control cylinder, 6. Hydraulic fluid on the
rod side of the bucket cylinder flows through passage NOTE: REGEN position does not work for hydraulic
“B1”, and to the “A1” passage where it is combined motors or single acting cylinders.
35-67
8
6
7
3
50035592
128
Roll Back/Lift Control-Neutral fluid from the piston side of the bucket control
When the control lever, 5, is moved to the roll back cylinder flows through passage “A1” and exits the
position, the bucket control spool, 2, is moved valve at port “T”, back to the relief/diverter valve
outward. Fluid flow from the hydraulic pump, 3, is manifold, 4. Fluid is then returned to the hydraulic
directed to the bucket control spool, through check fluid reservoir, 7.
valve #1, and to passage “B1”. From there hydraulic
fluid is directed to the rod side of the bucket control Since the lift control spool, 1, remains in neutral, the
cylinder, 6. As the bucket is being rolled back, the lift control cylinders, 8, remain in a fixed position.
35-68
8
6
7
3
50035593
129
Neutral/Lift Control-Raising the “A2” passage. The fluid then exits the valve body
When the control lever, 5, is moved to the raising through the “T” port, to the relief/diverter manifold, 4,
position, the lift control valve spool, 1, is moved and then to the hydraulic fluid reservoir, 7. This allows
outward. Fluid flows from the hydraulic pump, 3, the implement boom to raise.
opens check valve #2, and is directed through
passage “B2”. Fluid is then directed to the piston side Since the bucket control spool, 2, remains in the
of the lift control cylinder, 8. The hydraulic fluid on the neutral position, the bucket control cylinder remains
rod side of the lift cylinder flows out of the cylinder to in a fixed position.
35-69
8
6
7
3
50035594
130
Neutral/Lift Control-Lowering body through port “T”. Fluid then returns to the
When the control lever, 5, is moved to the lowering hydraulic fluid reservoir, 7, through the relief/diverter
position, the lift control spool, 1, is moved inward. manifold, 4. This action allows the implement boom
Fluid flow from the hydraulic pump, 3, opens check to lower.
valve #2, and fluid flows through passage “A2”, to the
rod side of the lift control cylinder, 8. The hydraulic Since the bucket control spool, 2, remains in the
fluid on the piston side of the cylinder flows out of the neutral position, the bucket control cylinder remains
cylinder, through passage “B2”, and out of the valve in a fixed position.
35-70
8
6
7
3
50035595
131
Neutral/Lift Control-Float pressure is directed out of the valve body through the
When the control lever, 5, is moved to the float power beyond (PB) port and to the relief/diverter
position, the lift control spool, 1, is moved inward manifold, where it is then directed to the main
beyond the normal lowering position. In this position, hydraulic system.
passages “A2” and “B2” are interconnected, and fluid
is free to move between the rod and piston sides of Since the bucket control spool, 2, remains in the
the lift control cylinder, 8. this allows the lift arms of neutral position, the bucket control cylinder remains
the loader to move up and down as the loader bucket in a fixed position.
passes over uneven terrain. Hydraulic pump fluid
35-71
Op. 35 204
OVERHAUL
REAR (SINGLE-SPOOL) REMOTE VALVE

Removal
1. Thoroughly clean the area around the remote 2
control valve and disconnect the remote tubes, 1,
from the valve.
2. Disconnect the lever, 2, from the valve spool and

body.
3. Remove the mounting nuts, 3, and remove the

valve from the lift cover. 3
1
KIT #1
132
KIT #2
133
35-72
Disassembly
1. Remove bolts, 11, and remove the bracket, 10,
and plate, 7.
2
6
2. Remove bolts, 9, end cap, 8, and withdraw the 13
spool, 2, with bolt, 5, spring seats, 3, spring, 4, 12
plate, 7, washer, 14, seal washer, 13, and O ring,
14
6, from the body, 1.
3. Remove O ring, 6, from the spool bore on the op- 6

posite end of the valve body.
4. Remove the O rings, 12. 9
5. Remove bolt, 5, and separate the spring, 4, and 8 5

spring seats, 3, if necessary.
3 3 7
4 7 1 10
Inspection 11
1. Inspect the spool and spool bore for pitting,
scratches, or excess wear. If inspection reveals
defects, replace the control valve assembly. 134
1. Valve Body 8. Endcap
2. Check that the spool moves freely in the spool 2. Valve Spool 9. Bolt
bore. If defective, replace the control valve as- 3. Spring Seat 10. Clevis
sembly. 4. Spring 11. Bolt
5. Bolt 12. O ring
6. O ring 13. Seal Washer
Assembly 7. Retainer 14. Washer
1. Assemble the spring seats, 3, and spring, 4, with
bolt, 5.
2. Install new O ring, 6, in the spool bore of the valve

body.
3. Install plate, 7, washer, 14, seal washer, 13, and

O ring, 6, over the spool, 2, and insert the assem-
bly into the bore in the valve housing.
4. Install the end cap, 8, and secure with bolts, 9.
5. Install plate, 7, bracket, 10, and secure with bolts,

11.
35-73
FRONT (DOUBLE SPOOL) REMOTE VALVE

Removal 4 3
1. Remove the three bolts, 1, securing the control
valve cover, 2, to the valve.
1
2. Slide the joystick boot, 3, towards the top of the
joystick, 4.
3. Loosen the lock nut, 5, on the joystick, 4, and 5
unscrew the joystick from the valve linkage, 6.
6
4. Remove the cover, 2.
20032849
135
IMPORTANT: Before disconnecting or removing
hydraulic lines from the control valve, label or mark
each tube for proper re-assembly.
5. Disconnect the hydraulic tubes, 1, from the 2

control valve, 2. Cap and plug all openings.
Remove the three bolts, 3, securing the valve, 2,
to the fender. Remove the control valve.
1
20035166
136
35-74
34
32
33
28
27
30
31
26
29 2 1
23 25 26
24
3 6
5
25 7
22 8
9
17 14
10
11 15
36
12
18
13
19 35
16 6
20 37 8 7
38 9 1
10
11
12
38
16 2
35
4
21
20043755 39 13 5
137
1. Cap Screws 11. Spring 21. Plug 30. Spring
2. End Cap 12. Stop Cup 22. Socketed Screw 31. E Clip
3. Float Detent Sleeve 13. Spacer (3/16″ x 24 x 3/4) 32. Roll Pin
4. REGEN Detent Sleeve 14. Float Spool 23. Joystick Flange 33. Lockout Pin
5. Retainer 15. REGEN Spool 24. Rod End 34. Knob
6. Poppet 16. O ring 25. Rod End Assemblies 35. Plug
7. Detent Spring 17. Check Plug 26. Nuts (5/16 N.F.) 36. Plug
8. Detent Balls 18. O ring 27. Cap Screw 37. O ring
9. Detent Retainer 19. Spring 28. Clevis 38. O ring
10. Washer 20. Loads Check Poppet 29. Spool Stud 39. O ring
35-75
Disassembly Assembly
1. Remove the three nuts, 26, that retain the joys- 1. Lightly lubricate and replace all O rings on valve
tick flange assembly to the control valve. plugs and spool orifices.
2. Remove the E clip, 31, that retains the lockout 2. Install each load check poppet, 20, spring, 19, and
pin, 33, and spring, 30, in the clevis, 28. check plug, 17, into the load check ports. Torque
the check plugs to 27 - 34 N⋅m (20 - 25 ft. lbs.).
3. Remove the cap screws, 27, which retain the cle-
vis, 28, to the valve body. 3. Install plugs, 21, 35, and 36, into the valve body.
Torque the plugs to 27 - 34 N⋅m (20 - 25 ft. lbs.).
4. Remove the float spool cap screws, 1, carefully
pull the float spool end cap, 2, off of the valve 4. If the detent retainer, 9, washer, 10, spring, 11,
body. and stop cup, 12, were removed from either
spool, reassemble parts onto spool and torque to
NOTE: The valve spool detent balls, 8, are under
7 - 10 N⋅m (5 - 7 ft. lbs.).
pressure and may be expelled when the float detent
sleeve, 3, is removed. Use a rag to catch the detent 5. Carefully install the REGEN spool, 15, into the
balls as the sleeve is being removed to avoid losing spool’s respective bore in the valve body.
the detent balls.
6. Install the spacer, 13, and retainer, 5, over the
5. Carefully remove the float detent sleeve, 3, until spool assembly
the detent balls, 8, snap free. NOTE: The float detent sleeve, 3, has a groove on
6. Remove the poppet, 6, detent spring, 7, retainer, the inside bore, the REGEN detent sleeve, 4, does
5, and spacer, 13. not.
NOTE: Be sure to make note of which valve spool 7. Using a punch or other suitable device, com-
bore each valve spool is removed from, as the float press the spring, 7, and poppet, 6, into the detent
and REGEN spools are not interchangeable within retainer, 9. Install the detent balls, 8, and REGEN
the spool bores. detent sleeve, 4, over the detent retainer, 9.
7. Gently remove the float spool, 14, with the stop 8. Install the end cap, 2, onto the REGEN spool as-
cup, 12, spring, 11, washer, 10, and detent retain- sembly. Secure the cap with cap screws, 1. Torque
er, 9, from the valve body. the cap screws to 11 - 15 N⋅m (9 - 11 ft. lbs.).
8. Remove the REGEN spool, 15, in the same man- 9. Install the float spool assembly into the valve
ner as described for the float spool in steps 4 body following assembly steps 6 - 9.
through 7. 10. Install the clevis, 28, onto the valve body and se-
9. Remove plugs, 21, 35, and 36, from the valve cure with cap screws, 27. Torque the cap screws
body. to 11 - 15 N⋅m (9 - 11 ft. lbs.).
10. Remove each check plug, 17, spring, 19, and 11. Install the lockout pin, 33, and spring, 30, into the
load check poppet, 20, from the check valve clevis, 28, and secure with E-clip, 31.
ports. 12. Install the joystick flange assembly onto control
valve. Apply LocTite 680 to the threads of the rod
Inspection end assembly, 25, and to the spool stud, 29. Se-
cure with the three nuts, 26, and torque to 10 N⋅m
1. Remove and discard all O rings from the valve
(7 ft. lbs.).
plugs and spool orifices in the valve body.
2. Inspect the valve spools and spool bores for pitting,
scratches, or excess wear. If found to be defective,
replace the remote control valve assembly.
3. Check that the float spool and REGEN spool
move freely within their respective bores. If found
to be defective, replace the remote control valve
assembly.
4. Inspect all springs for distortion. Replace if found
to be defective.
35-76
5
5
6
6
1
2
8
7
3
8 4 9
20000061
138
1. Control Valve Cover 4. Hydraulic Lines 7. Joystick Locknut
2. Bolt 5. Bolt 8. Joystick
3. Control Valve 6. Right Tractor Fender 9. Relief/Diverter Valve
Installation 3. Tighten the nuts, 3, that secure the control valve,

1. Install the control valve, 1, onto the right fender, 1, to the right fender, 2.
2. Secure with the two nuts, 3. Do not tighten nuts
4. Install the joystick, 5, onto the control valve, 1.
at this time.
Tighten joystick locknut, 6.
2. Install the hydraulic lines, 4, onto the control
5. Install the control valve cover, 7, onto the control
valve, 1. Do not overtighten hydraulic line fittings.
valve, 1, secure with the three retaining bolts, 8.
35-77
35-78
SECTION 41 -- STEERING -- CHAPTER 1
Chapter 1 -- Steering
CONTENTS

41 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
41 206 Power Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 216 Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 216 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
41 200 Power Steering Operation -- 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fluid Flow -- Neutral Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
41 200 Fluid Flow -- Left Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
41 200 Fluid Flow -- Right Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
41 200 Manual Operation -- 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump, Steering Motor, and Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
41 204 Steering Control Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
41-1

41 216 Steering Cylinder -- 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
41 206 Pump and Reservoir Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
41 206 Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
41-2
SPECIFICATIONS
POWER STEERING SYSTEM
Power Steering Pump

Flow @ 2600 rpm, 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.4 lpm (5.13 gpm)
Power Steering Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full Hydraulic
Steering Cylinder
Stroke 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 mm (8.86 in.)
Bore 2WD and FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm (1.57 in.)
Relief Valve Pressure
FWD and 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-105 bar (1450-1520 psi)
Reservoir
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 l (1.5 US qts.)
Oil CIH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Maximum Turning Angle

2-Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59°
FWD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54°
Front to Rear Axle Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66 to 1
41-3

4T, 4.8 3.6 -- 5.1 4.9 -- 6.9
M6 7T, 8T, 8.8 1.0 6.1 -- 8.3 8.3 -- 11.3 ------------ ------------ ------------
10T, 11T 8.6 -- 11.6 11.7 -- 15.7
4T, 4.8 9.4 -- 12.3 12.7 -- 16.7 11.2 -- 14.9 15.2 -- 20.2
M8 7T, 8T, 8.8 1.25 16.7 -- 21.0 22.6 -- 28.4 1.0 19.6 -- 25.3 26.5 -- 34.3
10T, 11T 21.0 -- 26.8 28.5 -- 36.3 22.4 -- 29.7 30.4 -- 40.2
4T, 4.8 18.8 -- 24.6 25.5 -- 33.3 21.0 -- 26.8 28.5 -- 36.3
M10 7T, 8T, 8.8 1.5 32.5 -- 41.3 44.1 -- 55.9 1.25 36.2 -- 46.3 49.0 -- 62.8
10T, 11T 39.8 -- 51.3 54.0 -- 69.6 42.7 -- 54.2 57.9 -- 73.5
4T, 4.8 27.5 -- 34.8 37.3 -- 47.1 31.8 -- 40.5 43.1 -- 54.9
M12 7T, 8T, 8.8 1.75 48.5 -- 61.5 65.7 -- 83.3 1.25 54.9 -- 69.4 74.5 -- 94.1
10T, 11T 68 -- 85.6 92 -- 116 73.1 -- 93.7 99 -- 127
4T, 4.8 46.3 -- 59.3 62.8 -- 80.4 51.4 -- 64.4 69.7 -- 87.3
M14 7T, 8T, 8.8 2.0 76.8 -- 97.4 104 -- 132 1.5 85.6 -- 109 116 -- 148
10T, 11T 102.6 -- 129 139 -- 175 110 -- 136 149 -- 185
4T, 4.8 63.5 -- 81.2 86 -- 110 67.2 -- 84.9 91 -- 115
M16 7T, 8T, 8.8 2.0 110 -- 136.5 149 -- 185 1.5 116 -- 142 157 -- 193
10T, 11T 151.3 -- 188 205 -- 255 162 -- 199 220 -- 270
4T, 4.8 83.4 -- 104 113 -- 141 96.7 -- 120 131 -- 163
M18 7T, 8T, 8.8 2.0 145 -- 174 196 -- 236 1.5 169 -- 206 230 -- 280
10T, 11T 203 -- 246 275 -- 333 220 -- 270 299 -- 367
4T, 4.8 106 -- 133 144 -- 180 126 -- 155 171 -- 211
M20 7T, 8T, 8.8 2.5 177 -- 214 240 -- 290 1.5 203 -- 245 275 -- 333
10T, 11T 268 -- 252 363 -- 341 293 -- 358 397 -- 485
41-4
SPECIAL TOOLS
Tool No.
Gauge 0-3000 psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OEM 1462
Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procure Locally
Tee Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #CNH299061, CIH #CAS2793
Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NH #FNH0027, CIH #CAS2794
Male Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Included with NH #CNH299061, CIH #CAS2793
Female Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Included with NH #CNH299061, CIH #CAS2793
VARISEAL Installation tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293955*
*Order thru Case IH Parts system.
41-5
Op. 41 206
POWER STEERING PUMP

The power steering pump, 1, is mounted on the front
right side of the engine and is driven by the engine oil
pump gear. Other than replacing the pump seals, 1
there is no maintenance for the pump. Should any of
the pump components fail, the entire pump assembly
must be replaced.
30996355
1
STEERING CYLINDERS
3
Op. 41 216
2WD AND FWD

The power steering cylinders, 1, are mounted
transversely under the tractor with the cylinder end,
2, pinned to the axle. The cylinder rod end, 3, is
pinned to the axle, and the rod attached to the spindle
arm, 4.
2 1 4
2WD
2
4
1
2 FWD
3
41-6
6
T
P
5
7 8 2
4
1. Sleeve 6. 6.Cylinder
2. Spool 7. Check Valve Assembly
3. Relief Valve Assembly 8. Gerotor Gear Pump
4. Reservoir 9. Kick Back Check Valve
5. P/S Pump
Op. 41 200 In the neutral position the fluid flows through the
POWER STEERING OPERATION -- 2WD hollow spool and returns to the reservoir via port “T”.
AND FWD Passage to ports “L” and “R,” leading to the cylinder,
Fluid Flow -- Neutral Position 6, are blocked by the second spool and sleeve. Fluid
Pressurized fluid from the power steering pump contained in the tubes and cylinder is trapped and the
enters the valve body at port “P”. The fluid flows cylinder remains in a fixed position. In this position
through the check valve, 7, past the relief valve, 3, the front wheels hold at a straight ahead position.
and through radial holes in the sleeve, 1, to the center Because the system is fully hydraulic, there is no
of the valve spool, 2. road feel or front wheel reaction transmitted to the
steering wheel.
NOTE: There are 24 radial holes in the sleeve, 1, that
index with 12 grooves provided in the spool.
41-7
T 6
P
5 7 8
2
5
5. P/S Pump
Op. 41 200 flows through passages “C,” “B,” and “A,” to port “L”
and to the power steering cylinder.
Fluid Flow-Left Turn
Turning the steering wheel to the left rotates the valve Fluid enters the cylinder barrel end of the cylinder
spool and indexes grooves in the spool with holes in and causes the front wheels to turn left. Fluid
the sleeve allowing fluid flow to enter passages “F,” contained in the cylinder rod side returns to the
“E,” and “D” in the control valve gear pump. Because control valve through port “R” and is directed back to
the gear pump is turning counterclockwise, the fluid the reservoir through port “T”.
41-8
6
T
P
7 2
5
8
6
5. P/S Pump
Op. 41 200 Fluid flow from the pump enters the gear pump
passages “A,” “B,” and “C” and flows out passages
Fluid Flow-Right Turn
“D,” “E,” and “F” to the valve port “R” to the cylinder.
Turning the steering wheel to the right (clockwise) Fluid in the piston side of the cylinder returns to the
rotates the spool clockwise and indexes the grooves control valve through port “L” and is directed back to
in the spool with holes in the sleeve for right turn. the reservoir through port “T”.
41-9
6
T
P
7 2
5
8
7
1. Sleeve 6. Cylinder
5. P/S Pump
Op. 41 200 to the direction that the steering wheel is being

MANUAL OPERATION -- 2WD AND FWD turned. Fluid from the opposite side of the cylinder
returns to the control valve. A check valve, 9, located
In the event of a power steering pump failure or in the connecting passage between the “T” and “P”
engine shut-down, the steering system can be passages, unseats and allows the fluid and any
operated manually. reservoir fluid that may be required to flow through
the check valve and connecting passage to the “P”
Turning the steering wheel drives the rotor and fixed
port passage, supplying the fluid required for the
ring gear pump, 8, in the control valve assembly to
pressure side of the system.
force fluid to the power steering cylinder, 6, according
41-10
TROUBLESHOOTING
Most malfunctions in the steering system can usually 2. Use a jack to raise the front end of the tractor off
be traced to dirt or foreign matter in the system. Dirt the ground, and cycle the steering from stop to
can cause such things as stickiness, erratic stop to check for front axle binding.
operation, or hard steering.
3. Be sure the hydraulic hoses from the pump-to-
Before considering the procedures below, follow the motor, and from the motor-to-cylinder, are
these suggested steps: connected correctly.
1. Check the pump for proper, relief valve action.

See “Pressure Testing,” discussed later in this
section.

Hard Steering 1. Control valve unit
• Control valve unit not aligned Reposition control valve unit. (If
to steering column loosening its mounting bolts lightens
the handwheel, it means that control
valve unit was in misalignment)
• Spool-and-sleeve combina- Replace

tion is seized because of
foreign matter
• Over tightening of the end Re-tighten to the specified torque
cap bolts limit
2. Oil pump
• The pump is stuck and will Replace oil pump
not work
• The pump is worn down Replace oil pump
• Pumping performance inad- Test pump performance, and if

equate necessary, remove the pump. Disas-
semble the pump and inspect the
internal seals. Refer to the pump seal
kit repair section
3. Relief valve
• The valve is damaged be- Replace control valve assembly
cause of internal deteriora-
tion
• Pressure setting is too low Replace control valve assembly
Steering wheel will not return to 1. Control valve unit

neutral or will turn by itself
• Spool and sleeve combina- Replace control valve assembly
tion is stuck and will not
rotate
• Control valve unit not aligned Re-align

to steering column
41-11

Cylinder will not follow steering 1. Control valve unit
wheel rotation or will respond
sluggishly
• Control valve unit has been Repair
improperly rebuilt, resulting
in valve mistiming
2. Steering cylinder
• Air is trapped in the cylinder Bleed air out
• Internal oil leakage because Replace the seal

of damaged piston seal
Steering wheel will “kick back” 1. Control valve unit

• Control valve unit has been Repair
improperly rebuilt, resulting
in valve mistiming
2. Piping
• Pipes are improperly con- Correct the pipe connections
nected to the four ports of
control valve unit
Oil leakage
• From the splined con- 1. Leaky oil seal Replace the seal
nection of column to
• Dirty hydraulic oil Change the oil
spool
• From mated face joints 2. Damaged O ring Replace

(valve body, spacer
plate, control valve unit,
end cap)
Front wheel shimmy 1. Worn pivot shaft and/or bushings 1. Replace pivot shaft and/or bush-
ings
2. Loose tie-rod 2. Tighten tie-rod
3. Loose spindle arm 3. Tighten spindle arm
4. Worn king pin and/or bearing 4. Replace king pin and/or bushing
Loose spindle 1. Worn bushing 1. Replace bushing

2. Worn spindle shaft 2. Replace spindle shaft
3. Worn or damaged thrust bearing 3. Replace thrust bearing
Hard steering 1. Faulty power steering system 1. Inspect and repair power steer-
ing system
41-12
PRESSURE TESTING
PUMP, STEERING MOTOR, AND RELIEF

VALVE 2
1. With the tractor engine stopped, disconnect one 4
of the hydraulic tubes, 1, at the frame, that run to
the steering cylinder.
1
NOTE: To adapt tee fitting (NH #CNH299061, CIH
CAS#2793) to 7/16-20 UNF female hose, use adapt-
er (NH #FNH0027, CIH #CAS2794) (7/16-20m UNF
x 9/16-18f). Use (#6 JIC-9/16-18m) plug, and (#6
JIC-9/16-18f) that is included with the tee fitting (NH
#CNH299061, CIH #CAS2793). 3
8
2. Connect a tee fitting, Tool No. (NH #CNH299061,
CIH #CAS2793), 3, and a 0-3000 psi pressure
gauge, 4, to the end of the tube, 1, from the steer-
ing motor, and cap the line, 2, leading to the
steering cylinder.
3. Install a cap, 2, into the open end of the tee.
FNH 00227 -- Adapter
4. Start the tractor engine, and allow it to idle. Ob-
serve the pressure gauge, it should indicate 0 psi.
5. Turn the steering wheel so that the line that the
gauge is connected to receives steering pump CNH 299061 -- Tee
fluid pressure intended for the steering cylinder.
For example, if the gauge is connected to the left 20004751/20004752
side of the cylinder, as viewed from the opera- 9
tor’s seat, turn the wheel to the left. Observe the
gauge and the following:
Test Results
If the pressure gauge reading rises before the
steering wheel is turned, it indicates that the
steering motor will have to be disassembled and
inspected.
If the pressure gauge reading is 1450-1520 psi
(100-105 bar) for the 2WD and FWD, when the
steering wheel is turned, the steering pump relief
valve is working properly.
If the pressure gauge reading is below the relief
valve setting, it may indicate that the relief valve is
not working properly, or the pump parts are worn.
6. Stop the tractor engine.

NOTE: The steering system relief valve, 1, is located 1
on the top side of the steering motor. Rotate the relief
valve cap clockwise to increase the pressure and
counterclockwise to decrease the pressure. 30996358
10
41-13
STEERING CYLINDER
After testing the steering motor relief valve, set up the
system as follows to test the steering cylinder:
NOTE: Use same fittings (NH #FNH0027, CIH

#CAS2794) adapter, and (NH #CNH299061, CIH
#CAS2793) tee fitting as used in Pump, Steering,
Motor, and Relief Valve test.
1. Remove the caps from the tee fitting, 2, and

steering cylinder connections.
1 2
2. Attach the tee fitting, 2, to the steering cylinder
connection, 1.
3. Start the tractor engine and turn the steering
wheel so that the line which the gauge is con- 11
nected to will receive the fluid pressure from the
pump. Observe the gauge when the steering link-
age reaches the limit of its travel.
4. Repeat the procedure for the other side of the cyl-
inder. Observe the following:
Test Results
If the pressure rises to the relief valve setting of
100-105 bar (1450-1520 psi) for the 2WD and
FWD, at both stops, it indicates that the system
is operating properly.
Repeat the procedure for the opposite side of the
cylinder.
41-14
OVERHAUL
Op. 41 204
STEERING CONTROL MOTOR
Removal
1. Remove the right and left rear hood sections, 1,
and 2, from the tractor.
2 1
30996356
12
2. Loosen and remove the drain bolt, 1, and drain
the fluid from the power steering reservoir, 2, into
a suitable container.
1
30996357
13
3. Disconnect the power steering tubing, 1, from the
power steering control motor, 2. Cap and plug all 4
openings.
4. Remove the four mounting bolts, 3.
1
3
5. Remove the steering column, 4, before removing
the power steering control motor, 2.
6. Remove the power steering control motor, 2.
2
1
30996358
14
41-15
Disassembly
(See attached for art references)
1. Loosen and remove the seven bolts, 1, from the
cover, 2.
24701
15
2. Remove the cover, 1, by sliding it to the side.
24702
16
NOTE: The inner rotor separates easily from the out-
er pump body rotor. Use care in handling, being care-
ful not to drop or damage these components. 1
3. Remove the rotor fixed ring, 1, and the rotor.
4. Remove and discard the two O rings from the ro-
tor fixed ring.
24703
17
41-16
5. Lift the drive shaft, 1, from the housing, 2.
1
2
24704
18
6. Remove the thrust plate, 1, by sliding it to the
side.
1
24705
19
7. Remove the threaded plug in the check valve
hole.
24706
20
41-17
8. Remove and discard the O ring from the control
valve.
24707
21
9. Rotate the control valve body and remove the
check valve ball, 1.
NOTE: The check ball, 1, is located in the deepest
bolt hole. Mark the hole after removing the ball.
27856
22
10. Position the control valve body so that the sleeve
control shaft trim pin is in a horizontal position.
11. Push the rotating valve inwards, so that the
valve, the valve seat sleeve and the thrust bear-
ing can be removed from the control valve body.
24709
23
41-18
12. Remove the two thrust washers, the thrust bear-
ing, and the spring retaining ring from the valve
seat sleeve.
24710
24
13. Remove the valve sleeve trim pin, 1, from the ro-
tating valve assembly.
1
24711
25
NOTE: On assembly, two reference marks were
made on the rotating valve and the sleeve, corre-
sponding to the neutral position maintained by the
springs. Before removing the springs, check that the
marks are clearly visible, otherwise renew them.
24712
26
41-19
14. Remove the rotating valve spool, 1, from the
valve seat sleeve, 2.
2
1
24713
27
15. Carefully remove the centering springs, 1, from
the neutral position in the rotating valve spool, 2.
1
2
24714
28
16. Remove and discard the dust seal and the VARI-
SEAL seal from the control valve body.
20428
29
41-20
17. Remove the threaded plug and the washer on the
pressure relief valve.
20434
30
18. Remove the pressure relief valve calibration ad-
justment screw.
27859
31
19. Turn the control valve body over and complete
disassembly by removing the spring, 1, and the
pressure relief valve piston, 2.
20436
32
41-21
20. Pressure relief valve components, (order of dis-
assembly-assembly).
1. Pressure relief valve
2. Pressure spring 1 2 3 4 5
3. Calibration adjuster screw
4. Seal washer
5. Plug
27099
33
Inspection
1. Thoroughly clean all parts in a suitable solution
and air dry.
2. Lightly lubricate all parts with Hy-Tran Ultra hy-
draulic fluid before assembly.
3. Inspect the spool and sleeve for evidence of
sticking, scuff marks, and any other damage. If
found defective, replace the spool and sleeve as
a matched marked set.
4. Check the pin to make sure it is not bent or
cracked. Check the internal teeth on the spool for
damage.
5. Inspect the inside surfaces of the housing for
wear or damage.
6. Inspect the rotor fixed ring and the rotor for wear.
7. Inspect the drive shaft for wear or damage.
8. Inspect the thrust bearing for wear or damage.
9. Inspect the centering springs for distortion. Cen-
tering springs that have lost their tension should
be replaced.
Assembly
1. Slide the spool into the sleeve. Position the spool
so that the centering spring slots, 1, and the refer- 2
ence marks, 2, on the spool and the sleeve line 1
up, so that the centering springs can be installed.
24712
34
41-22
2. With the centering springs positioned, insert the
centering springs into the slots in the spool and
sleeve.
24728
35
3. After inserting the springs in the rotating valve,
align and center the springs.
24729
36
4. Fit the neutral position spring retaining ring, 1, on
the valve sleeve, 2. The retaining ring must turn 2
freely on the rotating valve sleeve.
24730
37
41-23
5. Insert the rotating valve trim pin, 1, through the
spool and sleeve, 2. 2
24731
38
6. Install the two thrust washers and the thrust bear-
ing onto the rotating valve.
24732
39
7. Install the thrust washers and the thrust bearing
in the orientation shown. 1
1. External thrust washer
2. Thrust bearing 2
3. Internal thrust washer
4. Rotating valve 3
5. Rotating valve seat sleeve
4
8. Position the control valve body so that the hous-
ing seat on the rotating valve sleeve is positioned 5
horizontally.
24733
40
41-24
9. Lubricate the VARISEAL seal, 3, with grease and
fit on the outer edge of the guide bushing, 1, of
tool 293955, 2.
27824
41
10. Position the special tool 293955 complete with
components, 1 and 2, and the VARISEAL seal, 3,
on the control valve body, 4.
11. Push in while simultaneously turning the outer
bushing, 1, on the tool, in order to seat the VARI-
SEAL seal, 3, into the control valve body, 4.
12. Using the bushing, 1, press on the shaft, 2, in the
direction indicated by the arrow, in order to over-
come the pressure exerted by the inner spring.
Extract the tool from the control valve body when
the tapered part of the shaft, 2, is released from
the seal, 3. 27825
42
13. Orient the spool and sleeve so that the pin is hori-
zontal to the bench and carefully insert the as-
sembly into the bottom of the control valve body.
Rotate the assembly slightly while inserting it to
ease installation.
24739
43
41-25
NOTE: The check valve ball is located in the deepest
bolt hole.
14. Rotate the control valve body and insert the

check valve ball into the hole indicated.
24741
44
15. Install the check valve plug into the same hole as
the check valve ball.
NOTE: The check valve plug must be below the sur-
face of the control valve body.
24742
45
16. Lubricate a new O ring and install in the seat of
the control valve body.
24746
46
41-26
17. Fit the thrust plate, so that the holes align with the
holes in the control valve body.
24748
47
18. Make a reference mark on the teeth, 1, of the ro-
tor drive shaft that corresponds with the position 1
of the valve sleeve trim pin, 2. This is important
for correct timing of the rotor.
19. Install the rotor shaft, 1, into the control valve
body, making sure to align the rotor shaft with the 2
trim pin in the sleeve.
48
20. To re-fit the rotor, use the following:
-- Each time the steering control motor is
disassembled, turn the rotor over to limit
wear to the splined coupling area.
-- Observe the drawing for the correct timing
between the rotor, rotor drive shaft, and the
trim pin.
-- Fit the rotor onto the drive shaft, remember-
ing that correct timing is obtained by aligning 1
the teeth, 1, on the trim pin axis plane, with
the centerline of one compartment on the
rotor. 24750
49
41-27
21. Lubricate the two O rings, 1, with clean hydraulic
fluid and install one O ring in each side of the rotor
fixed ring.
24751
50
22. Install the cover, aligning the retaining holes with
those present on the rotor fixed ring.
24753
51
23. Install the special bolt into the check valve hole.
24754
52
41-28
24. Install the remaining six bolts through the cover
and into the control valve body, and tighten in a
diagonal sequence See “Bolt Torque Specifica-
24755
53
25. Install the pressure relief valve piston into the
seat as indicated.
24756
54
26. Install the pressure relief valve spring.
24757
55
41-29
27. Install the pressure relief valve calibration screw.
NOTE: Calibration will be done when the unit is
installed on the tractor, to the values discussed later
in the Pressure Testing section.
24758
56
28. Install the plug, 1, and tighten to a torque of 40 --
60 N⋅m (30 -- 44 ft. lb.).
20434
57
29. Lightly lubricate and install a new dust seal, 1, in
the seat in the control valve body, 2. 1
24764
58
41-30
Op. 41 204
Installation 4
1. Apply anti-seize to the splines of the steering 1
shaft before installing the steering column into 3
the steering control motor.
2. Install the power steering control motor, 2, and
the steering column, 4, on the tractor and secure
with the four retaining bolts, 3. Turn the steering 2
wheel back and forth to check for freedom of
movement. The spool should turn freely in the
motor. 1
30996358
3. Connect the power steering tubing, 1, to the pow-
er steering control motor, 2. Tighten and torque 59
the fittings to 50.9-59.7 N⋅m (37.5-44 ft. lb.).
4. Install the drain bolt, 1, and refill the power steer-
ing fluid reservoir, 2.
5. Start the engine and turn the wheels from stop to
stop until the relief valve begins to operate to
bleed air from the system. 2
6. Check for fluid leaks.
1
30996357
60
7. Install the right and left rear hoods, 1 and 2, onto
the tractor.
2 1
30996356
61
41-31
Op. 41 216
STEERING CYLINDER -- FWD
Removal
the fluid from the power steering reservoir, 2.
30996392
62
2. Disconnect the power steering hoses, 2, from the
steering cylinder, 1. Cap and plug all openings.
2
FWD
63
3. Loosen and remove the bolt, 2, and remove the
retaining pin, 1, from the axle housing.
2 1
30996389
64
41-32
4. Retract the steering cylinder slightly to allow the
cylinder end, 1, to be removed from the axle
housing, 2. Remove the steering cylinder end, 1,
from the axle housing, 2.
1 2
30996383
65
5. Loosen and remove the nut, 1, from the steering
arm stud. Remove the rod end of the cylinder
from the steering arm stud.
6. Remove the cylinder from the axle.
7. Repeat steps 1-5 for the cylinder on the opposite
side.
1 1
66
Op. 41 216
STEERING CYLINDER -- 2WD
Removal
30996392
67
41-33
2. Disconnect the power steering hoses, 1, from the
steering cylinder, 2. Cap and plug all openings. 1
20000919
68
retaining pin, 2, from the cylinder end, 3, and the 1
axle housing, 4.
2
20000920
69
retaining pin, 2, from the cylinder rod end, 3, and
the axle housing, 4. 1 2
5. Remove the cylinder from the axle.
20000918 4
70
41-34
16
1 6
8
10
13
14
2 15
7 4
5
9
11
12
3
20000921
14
71
Diagram of 2WD Steering Cylinder
1. Gland head 9. O ring

2. Cylinder barrel 10. U ring
3. Piston rod 11. Bushing
4. Nut 12. Wiper ring
5. Piston 13. Back-up ring
6. Back-up ring 14. Bushing
7. O ring-piston 15. Retaining ring
8. O ring-Gland head 16. Spherical Bearing
41-35
3 1
11
16 9
8 15
14
13
12
10
7
6
5
20000922
72
Diagram of FWD Steering Cylinders
1. Gland head 9. O ring-Gland head

2. Cylinder barrel-LH 10. O ring
3. Cylinder barrel-RH 11. U ring
4. Piston rod 12. Bushing
5. Nut 13. Wiper ring
6. Piston 14. Back-up ring
7. Back-up ring 15. Bushing
8. O ring-piston 16. Bushing
STEERING CYLINDER -- 2WD AND FWD

Disassembly
1. Use a suitable chisel to straighten the cylinder
barrel crimping, from the gland head, 1.
2. Use a spanner wrench to unscrew the gland
head, 1, out of the cylinder barrel, 2 and/or 3. Re-
move the piston rod, 4 and/or 17, and the piston
assembly from the cylinder barrel.
NOTE: Use care when removing the piston assem-
bly from the cylinder barrel, not to damage the finish
on the parts. Remove and discard O rings, wipers,
and seals. Use new during assembly.
3. Remove the piston nut, 5, the piston, 6, the back-

up rings, 7, the piston O ring, 8, the O rings, 9 and
10, the U ring, 11, the bushing, 12, the gland
head, 1, the wiper ring, 13, and the back-up ring,
14, from the piston rod, 4 and/or 17.
41-36
Inspection
1. Clean all parts in a suitable solvent and air dry.
2. Inspect the inside of the cylinder barrel for excess
wear, scuffing or scarring.
3. Inspect the piston for scuffing, score marks, or
other damage. Replace with new components if
damaged.
4. Use micrometers to measure the inside diame-
ter of the cylinder barrel, 2, and the outside di-
ameter of the piston, 1, to determine the working
clearance. Replace if the clearance is in excess
of 0.7 mm (0.028″).
5. Inspect the cylinder rod for excess wear, straight-
ness, and scoring. Replace if damaged.
20000923
73
6. Inspect the anchor pins, 1, and bearings, 2, for
excess wear and excessive clearance. Replace
the anchor pins and/or bearings if the clearance
20000925
74
7. Check the rod to gland head clearance. Replace
the bushing if the clearance is in excess of 0.3
mm (0.012″).
20000924
75
41-37
NOTE: If the spherical bearing is seized in the bore,
both the spherical bearing and the cylinder barrel
must be replaced.
8. On the two wheel drive model, measure the in-

side diameter of the cylinder spherical bearing
bore, 2, and the diameter of the spherical bear-
ing, 1. Replace the spherical bearing and the cyl-
inder barrel if the clearance, 3, is greater than 0.5
mm (0.019″).
9. On assembly, replace all O rings and seals with
new.
20000926
76
Assembly
1. If the gland head bushing, 1, needs to be re- 2
placed, use a suitable driver tool, 2, to install the
new bushing.
1
20000927
77
2. If the pin bushings need to be replaced, lubricate Seam
the bushing bore, 2, and the bushing, 1, with hy-
draulic oil. With the seam positioned as shown,
install the bushing using a suitable driver, 3.
20000929
78
41-38
3. On the two wheel drive cylinder, lubricate the
spherical bearing and the bearing bore with
grease, and press the bearing, 1, into the cylinder
bore, 2. Install a new retaining ring in the orienta-
tion shown.
20000930
79
4. Lubricate and install a new U ring seal, 11, in the
gland head, 1.
5. Lubricate and install a new wiper ring seal, 13, in
the gland head, 1, and secure with a new back-up
ring, 14.
6. Lubricate new O rings, 9 and 10, with petroleum
jelly and install in the O ring grooves on the gland
head, 1.
7. Lubricate the new O ring, 8, with petroleum jelly
and install on the piston, 6. Install new back-up
rings, 7, on the piston, 6.
8. Install the gland head assembly, the bushing, 12,
and the piston assembly, onto the piston rod, 4
and/or 17.
9. Install the piston nut, 5, on the piston rod, 4 and/or
17. Tighten the piston nut, 5, to 56 N⋅m (42 ft. lb.)
on the 2WD and the FWD cylinders.
10. Lubricate the cylinder barrel, 2 and/or 3, and the
piston assembly with clean hydraulic oil.
11. Carefully install the piston assembly into the cyl-
inder barrel, 2 and/or 3.
12. Tighten and torque the gland head, 1, to 127 N⋅m
(94 ft. lb.).
41-39
13. Stake the piston nut, 1, to prevent loosening.
2WD and FWD
20045745
80
14. Crimp the end of the cylinder barrel, 1, at the
gland head, 2, to prevent the gland head from
loosening.
20000931
81
Op. 41 216
STEERING CYLINDER -- FWD
Installation
1. Install the rod end of the steering cylinder onto
the steering arm stud. Install the nuts, 1. Tighten
to the specified torque. See “Bolt Torque Specifi-
cations”, discussed later in this section.
82
41-40
2. Retract the steering cylinder slightly to allow the
cylinder end, 1, to be installed in the axle hous-
ing, 2. Install the steering cylinder end, 1, into the
axle housing, 2.
1 2
30996383
83
3. Install the retaining pin, 1 and secure with the
bolt, 2. Tighten to the specified torque. See “Bolt
Torque Specifications”, discussed later in this
section.
2 1
30996389
84
4. Connect the steering hoses, 2, to the cylinder, 1.
Tighten to the specified torque. See “Specifica-
tions”, discussed later in this section. 2
85
41-41
5. Install and tighten the drain bolt, 1. Refill the pow-
er steering fluid reservoir, 2.
6. Start the tractor, and operate the steering sys-
tem, turning the steering wheel left and right, to
bleed the air from the system. Check for leaks.
7. Check the fluid level in the power steering fluid 2
reservoir, 2, and refill if necessary, to the proper
level.
1
30996392
86
Op. 41 216
STEERING CYLINDER - 2WD
Installation
1. Position the cylinder in the axle mounts, and
install the pin, 2, through the axle housing, 4, and
the cylinder rod end, 3. Secure with the retaining 1 2
bolt, 1.
20000918
4
87
2. Install the pin, 2, through the axle housing, 4, and
the cylinder end, 3, and secure with the retaining 1
bolt, 1.
2
20000920
88
41-42
3. Connect the steering hoses, 1, to the cylinder, 2.
Tighten to 36 N⋅m (25 ft. lb.). 1
20000919
89
4. Install and tighten the drain bolt, 1. Refill the pow-
er steering fluid reservoir, 2.
5. Start the tractor, and operate the steering sys-
tem, turning the steering wheel left and right, to
bleed the air from the system. Check for leaks.
6. Check the fluid level in the power steering fluid
2
reservoir, 2, and refill if necessary, to the proper
level. 1
30996392
90
41-43
Op. 41 206
PUMP AND RESERVOIR TANK
Pump Removal
1. Loosen and remove the drain plug, 1, and drain
30996392
91
2. Loosen the bottom hose clamp, 5, on the power
steering pump suction hose, 1. 5 1
3. Remove the suction hose, 1, from the power
2
steering pump, 2.
4. Remove the pressure tube (not shown) from the
bottom of the power steering pump, 2.
3
5. Loosen and remove the two retaining nuts, 3, and
the two retaining bolts (not shown), that secure
the power steering pump, 2, to the timing gear
cover, 4.
6. Remove the steering pump, 2, from the timing 30996393
4
gear cover, 4.
92
NOTE: The only service that can be done to the pow-
er steering pump is to replace the O rings and seals.
If any other part of the pump is damaged, the entire
unit must be replaced.
41-44
1
4
3
2
5
6
8
9
10 11
93
Disassembly
1. Place the pump in a soft jawed vise with the drive 3. Inspect all parts for damage or wear. If damaged
shaft facing downward. or worn, replace the entire pump assembly.
2. Scribe a line on the pump body for ease of orien-
tation during assembly. Assembly
3. Remove the four bolts, 1, securing the cover to NOTE: Use the scribe marks made during disassem-
the pump, and remove the cover, 4. bly to assemble the pump in its original orientation.
4. Remove the seal ring, 3, the back-up ring, 2, and 1. Install a new shaft seal, 11, and a new snap ring,
the outer, wear plate, 5. 10, in the pump housing, 9.
5. Remove the drive gear, 6, and the driven gear, 7, 2. Install a new inner, wear plate, 8, into the pump
from the pump housing, 9. housing, 9.
6. Remove the inner, wear plate, 8, from the pump 3. Install the drive gear, 6, and the driven gear, 7,
housing, 9. into the pump housing, 9.
7. Remove the snap ring, 10, and the shaft seal, 11, 4. Install a new outer wear plate, 5, new back-up
from the pump housing, 9. ring, 2, and a new seat ring, 3.
Inspection and Repair 5. Install the pump cover, 4, and secure with the
four bolts, 1. Tighten and torque the bolts, 1, to
1. Wash all parts in a clean solvent and air dry. 21 – 27 N⋅m (16 – 20 ft. lb.).
2. Discard all used O rings and seals, and use new
during assembly.
41-45
Op. 41 206
5 1
Pump Installation
1. Install the power steering pump, 2, onto the tim- 2
ing gear cover, 4.
2. Install and tighten the two retaining nuts, 3, and the
two retaining bolts (not shown), to secure the pow-
er steering pump, 2, to the timing gear cover, 4. 3
3. Install and tighten the pressure tube (not shown)

to the bottom fitting on the power steering pump,
2.
30996393 4
4. Connect the suction hose, 1, to the power steer-
ing pump, 2. 94
5. Install the bottom hose clamp, 5, to the bottom of
the suction hose, 1.
6. Install the drain bolt, 1, and fill the power steering
reservoir, 2, with clean fluid.
30996392
95
41-46
SECTION 44 -- 2WD FRONT AXLE -- CHAPTER 1
SECTION 44 - 2WD FRONT AXLE
Chapter 1 - 2WD Front Axle
CONTENTS

44 100 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
44 103 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
44-1
Op. 44 100
SPECIFICATIONS
King Pin Inclination 8°
Toe-In 0 ± 5 mm (0 ± 3/16 in.)
Caster (Fixed) 0°
Camber (Fixed) 3°
Pivot Shaft to Bushing Clearance .02 -- .15 mm (.001 -- .006 in.)
Wear Limit 0.3 mm (.012 in.)
Front Axle End Play 0.2 mm (.008 in.)

4T, 4.8 3.6 -- 5.1 4.9 -- 6.9
M6 7T, 8T, 8.8 1.0 6.1 -- 8.3 8.3 -- 11.3 ------------ ------------ ------------
10T, 11T 8.6 -- 11.6 11.7 -- 15.7
4T, 4.8 9.4 -- 12.3 12.7 -- 16.7 11.2 -- 14.9 15.2 -- 20.2
M8 7T, 8T, 8.8 1.25 16.7 -- 21.0 22.6 -- 28.4 1.0 19.6 -- 25.3 26.5 -- 34.3
10T, 11T 21.0 -- 26.8 28.5 -- 36.3 22.4 -- 29.7 30.4 -- 40.2
4T, 4.8 18.8 -- 24.6 25.5 -- 33.3 21.0 -- 26.8 28.5 -- 36.3
M10 7T, 8T, 8.8 1.5 32.5 -- 41.3 44.1 -- 55.9 1.25 36.2 -- 46.3 49.0 -- 62.8
10T, 11T 39.8 -- 51.3 54.0 -- 69.6 42.7 -- 54.2 57.9 -- 73.5
4T, 4.8 27.5 -- 34.8 37.3 -- 47.1 31.8 -- 40.5 43.1 -- 54.9
M12 7T, 8T, 8.8 1.75 48.5 -- 61.5 65.7 -- 83.3 1.25 54.9 -- 69.4 74.5 -- 94.1
10T, 11T 68 -- 85.6 92 -- 116 73.1 -- 93.7 99 -- 127
4T, 4.8 46.3 -- 59.3 62.8 -- 80.4 51.4 -- 64.4 69.7 -- 87.3
M14 7T, 8T, 8.8 2.0 76.8 -- 97.4 104 -- 132 1.5 85.6 -- 109 116 -- 148
10T, 11T 102.6 -- 129 139 -- 175 110 -- 136 149 -- 185
4T, 4.8 63.5 -- 81.2 86 -- 110 67.2 -- 84.9 91 -- 115
M16 7T, 8T, 8.8 2.0 110 -- 136.5 149 -- 185 1.5 116 -- 142 157 -- 193
10T, 11T 151.3 -- 188 205 -- 255 162 -- 199 220 -- 270
4T, 4.8 83.4 -- 104 113 -- 141 96.7 -- 120 131 -- 163
M18 7T, 8T, 8.8 2.0 145 -- 174 196 -- 236 1.5 169 -- 206 230 -- 280
10T, 11T 203 -- 246 275 -- 333 220 -- 270 299 -- 367
4T, 4.8 106 -- 133 144 -- 180 126 -- 155 171 -- 211
M20 7T, 8T, 8.8 2.5 177 -- 214 240 -- 290 1.5 203 -- 245 275 -- 333
10T, 11T 268 -- 252 363 -- 341 293 -- 358 397 -- 485
44-2
Op. 44 101
The standard 2WD front axle on the D35, D40 and
D45 consists of a center axle member, 1, and two
outer axle sections, 4. The center member is
mounted centrally to the frame by a pivot shaft, 5.The
axle rotates on the pivot shaft, thereby maintaining
the tractor chassis in a level position, and ensuring
stable operation even on irregular ground.
Each outer axle section is attached to the center axle

section by two bolts. The front axle is adjustable from
122-183 cm (48-72 in.) in width, by removing the two
bolts on each side, sliding the outer axles outward,
and replacing the two bolts.
1
1. Axle Center Section
2. Spindle Arm
3. Tie Rod
4. Outer Axle Section
5. Pivot Shaft
6. Tractor Frame
The outer axle sections, 1, accept the front wheel

spindles, 2. The spindles, 2, are supported by
bushings, 3, in the outer axle sections, and a thrust
bearing, 4, at the lower end of the axle section,
supports the vertical load.
The spindle, 2, acts as a king pin and keeps a

constant inclination to the axle.
The top of the spindles are splined, to accept the

spindle arms, 5, which are retained by a clamp bolt,
6. The wheel hub, 7, is supported on the wheel
spindle by two opposed tapered roller bearings, 8.A
nut, 9, is used on the spindle to retain the outer cone
and roller bearing assembly, and to provide a method
of bearing pre-load adjustment.
2
1. Outer Axle Assembly
2. Spindle
3. Bushing
4. Thrust Bearing
5. Spindle Arm
6. Clamp Bolt
7. Hub
8. Tapered Roller Bearings
9. Nut
44-3
The right and left spindle arms, 4, are connected
together with an adjustable tie rod, 3. The tie rod 2
adjustment is also used for making toe-in adjust-
ments. The power steering cylinder assembly, 1, is
located on the front axle, 2, and tie rod, 3.
4
1
30000956
TROUBLESHOOTING
TROUBLE POSSIBLE CAUSE
Front Wheel Shimmy Worn spindle shaft and/or bushings

Worn pivot shaft and/or bushings
Loose wheel hub nut
Loose spindle arm
Loose tie rod
Loose or damaged thrust bearing
Worn king pin and/or bearing
Hard Steering Spindle bushings lack lubrication
Damaged spindle shaft and/or bushings
Worn or damaged thrust bearings
Faulty power steering system
Loose Spindle Worn or damaged bushings
Worn or damaged spindle shaft
Worn or damaged thrust bearing
44-4
OVERHAUL
FRONT AXLE
Removal
1. Drain the hydraulic fluid from the power steering
reservoir into a suitable container.
2. Disconnect the power steering hoses from the
steering cylinder. Cap and plug all openings.
3. Place a floor jack under the transmission
housing.
4. Raise the front end of the tractor just enough to
take the weight off of the front axle.
5. Place jack stands under the engine side frame
rails.
6. Remove the axle pivot front bearing holder, 1,
from the frame.
1
30000959
4
7. Remove the axle pivot rear bearing holder, 1,
from the frame, and carefully roll the front axle out
from under the tractor. 1
30000960
44-5
Disassembly
3 6 3
9
9
7
5
5
8
7
6 4
2
10
20000957
6
1. Tractor Frame 6. Bushing
2. Front Axle Assembly 7. Thrust Washer
3. Bearing Holder 8. Shims
4. Outer Axle Assembly 9. Grease Fitting
5. Oil Seal 10. Bolt-Outer Axle Mounting
1. Loosen and remove the wheel mounting bolts, 1,

and remove the front wheels, 2, from the hub, 3.
1
3
30000961
44-6
2. Remove the retaining bolt, 1, and the steering
cylinder pin, 2, from both ends of the steering
cylinder. Remove the steering cylinder from the 1
axle. 2
3. Remove the cotter pin, 3, and the castle nut, 4, 3
from the tie rod, 5. Repeat for the opposite side.
5
4
30000962
8
4. Remove the ball joint pin, 3, from the spindle arm,
2. Repeat for the opposite side. Remove the tie
rod, 1, from the spindle arms, 2.
9
5. Remove the outer axle mounting bolts, 1, and
remove the outer axle and spindle assembly, 2, 3
from the main axle housing, 3.
2
1
30000963
10
44-7
6. Loosen and remove the three wheel cap
retaining bolts, 11, and remove the wheel cap, 1.
10
7. Remove and discard the wheel cap gasket, 2.
8. Remove the cotter pin, 12, the castle nut, 3, and
the washer, 4, from the axle shaft. 7
9. Remove the hub, 6, and the inner and outer 6
wheel bearings, 7 and 5, as an assembly.
10. Remove and discard the seal, 9, from the hub, 6.
4
11. Remove the inner wheel bearing, 7, and the outer
1
wheel bearing, 5, from the hub, 6. 2
9
11
5
3
12
11
12. Loosen and remove the spindle arm clamp bolt,
6, lock washer, 7, and nut, 8, from the spindle
arm, 1.
13. Remove the spindle arm, 1, from the spindle, 2.
14. Remove the spindle, 2, from the axle. 8 7
15. Remove the shim, 9, the spacer, 10, the thrust
bearing, 3, the thrust washers, 4, and the O ring,
5. Discard the O ring, 5.
9 1
10
6
2 3
4
12
44-8
Inspection
13
1. Pivot Pin 4. Bushings
2. Bearing Holder-Front 5. Shims
3. Bearing Holder-Rear 6. Oil Seal
1. Check the end play of the front axle pivot pin, 1. If the clearance is 0.3 mm (.012 in.), the bushings,
If the end play is .2 mm (.008 in.) add shims, 5, 4, will need to be replaced.
to the front bearing holder, 2, as required.
3. Check the inner and outer wheel bearings for
2. Measure the pivot pin, bearing journal diameter, and roughness, wear or uneven rotation when turned
the bushing, 4, inside diameter, to determine the by hand. Replace as necessary.
working clearance. Normal pivot shaft to bushing
NOTE: When replacing wheel bearings, replace the
clearance should be .02 - .15 mm (.001 - .006 in.).
bearings and the bearing race as a set.
44-9
4. Check the spindle bushings, 1, for excess wear
or damage. Replace the bushings as required.
NOTE: If bushings, 1, are replaced, install to a recess
depth of 8 mm (.315 in.).
5. Inspect the spindle thrust bearings for excess

wear or damage. Replace as necessary.
6. Inspect the spindle shank and axle bearing
journals for excess wear or damage. Replace as
necessary.
14
Assembly
1. Lubricate a new O ring, 5, with petroleum jelly,
and install into the spindle tube.
2. Lubricate with grease, the thrust bearing, 3, the
thrust washers, 4, the shim, 9, and the spacer, 10. 8 7
3. Install the spindle, 2, into the spindle tube with the
thrust bearing, 3, the thrust washers, 4, the shim,
9, and the spacer, 10.
4. Install the spindle arm, 1, onto the spindle, 2, and 9 1
secure with the spindle arm clamp bolt, 6, the
lock washer, 7, and the nut, 8. Tighten the nut, 8. 10
6
2 3
4
15
44-10
5. Lubricate and install a new seal, 9, in the hub, 6.
6. Pack the inner and outer wheel bearings, 7 and
5, with grease and install into the hub, 6.
10
7. Install the hub, 6, onto the axle shaft.

8. Install the washer, 4, and the castle nut, 3, on the 7
axle shaft. Tighten the castle nut, 3, slowly while 6
rotating the hub, 6, until the hub begins to drag.
Back off the castle nut to the next castellation.
4
9. Install a new cotter pin, 12. 1
10. Install a new wheel cap gasket, 2, and the wheel 2
cap, 1. 9
11. Secure the wheel cap, 1, with the three retaining 11
bolts, 11. Tighten the bolts.
5
3
12
16
12. Install the outer axle and spindle assembly, 2,
into the main axle housing, 3, and secure with the 3
retaining bolts, 1. Tighten the bolts.
2
1
30000963
17
13. Install the ball joint pins, 3, of the tie rod, 1,
through the spindle arms, 2.
18
44-11
14. Install the castle nut, 4, onto the tie rod, 5. Tighten
the nut, 4, to 275 - 333 N⋅m (203 - 246 ft. lbs.)
and secure with the cotter pin, 3. Repeat for the 1
opposite side. 2
15. Install the steering cylinder onto the axle. Install 3
the cylinder retaining pin, 2, and secure with the
retaining bolt, 1. 5
4
30000962
19
16. Install the wheels, 2, onto the hub, 3. Secure with
the wheel mounting bolts, 1. Torque the wheel
mounting bolts to 169 N⋅m (125 ft. lb.). 1
3
30000961
20
Op. 44 103
Installation
1
1. Install the axle pivot rear bearing holder, 1, onto
the frame.
2. Carefully roll the axle under the tractor, and
position on the rear bearing holder.
30000960
21
44-12
3. Install the axle pivot front bearing holder, 1, onto
the axle, and the frame.
4. Tighten all the axle pivot bearing holder mounting
bolts.
5. Remove the jack stands and lower the tractor to
the floor.
6. Remove the caps and plugs from the steering
hoses and the steering cylinder fittings.
7. Connect the power steering hoses to the steering
cylinder, and tighten the fittings. 1
8. Fill the power steering reservoir to the proper 30000959
level with Hy-Tran Ultra hydraulic fluid. 22
44-13
44-14
SECTION 50 - CLIMATE CONTROL - CHAPTER 1

DX40--DX45 With Cab
CONTENTS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Refrigerant Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Receiver/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HVAC Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cab Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning Cab Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compressor Protection Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
High-Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Low-Pressure Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab and Engine Bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Expansion Valve -- Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Temperature/Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Service Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Preventing Mixing of Service Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
50-1

Refrigerant Extraction and Recycling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Using Extraction Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Using Recycling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Recycling vs. Reclaiming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Containment of Air Conditioning Refrigerants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Recharging/Refilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Using a Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Checking Refrigerant for Excess Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Containers for Storing Recycled Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disposal of Empty or Near-empty Disposable Containers . . . . . . . . . . . . . . . . . . . 22
Applicable SAE Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Related SAE Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Manifold Gauges and Interpretations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Performance Test Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Evacuating the Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Vacuum Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
HVAC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Receiver/Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
50-2

Evaporator/Heater Core Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Blower Motor/Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Low Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
High Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
A/C Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Compressor Assembly Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Compressor Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Clutch Breakdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Compressor Repaired Internally and Reinstalled in the System . . . . . . . . . . . . . . 67
Sanden Compressor Replaced by a New Sanden Compressor
of the Same Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Clutch Head Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Keyed Shaft Armature Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Rotor Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Field Coil Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Field Coil Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Rotor Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Armature Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacement of Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Valve Plate Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Valve Plate and Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
50-3
SPECIFICATIONS
COMPRESSOR
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sanden International (U.S.A) Inc.
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 mm (1.38 in)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.6 mm (0.9 in)
Displacement per revolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 cc/rev
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
REFRIGERANT
System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Kg (2.40 lb) R134A
REFRIGERANT OIL
System Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 ml (4.56 fl. oz.) SP-20 PAG Oil
LOW PRESSURE SWITCH

Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ± 2 psig
Closing Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 ± 3 psig
HIGH PRESSURE SWITCH

Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400 ± 10 psig
Closing Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 ± 20 psig
50-4
SPECIAL TOOLS
Listed below are the tools required to service the A/C system. These tools listed are standard equipment. See
your authorized service dealer for more information.
Part Number Description

CAS10747A Sanden Compressor Tool Kit
OEM1486 Refrigerant Gas Leak Detector
FNH00890 Air Conditioning Spring Lock Coupling Tool
OEM1419 Service Gauge Set (R134A)
OEM1598 R-134A Recovery/Recycle and Recharging Station
OEM1662 Thermometer
50-5
DESCRIPTION AND OPERATION

COMPRESSOR
The compressor, 1, is mounted inside the engine
compartment and is driven by the crankshaft pulley.
Refrigerant and oil is moved through the air
conditioning system by the compressor, which
lubricates and cools the unit during operation.
An electromagnetic clutch is used to engage or

disengage the compressor as required when
operating the air conditioning system. The clutch is 1
of a stationary coil type and forms an integral part of
the compressor pulley assembly. When the coil is
energized, the clutch plate is pulled against the 86063996
rotating pulley. De-energizing the coil will allow the
plate to return to a standby position. 1
This system holds 1.1 kg (2.40 lbs) of R-134A

refrigerant. When the system is empty it will hold 135
ml (4.56 fl. oz.) of SP-20 PAG Oil.
CONDENSER
The condenser, 1, is located at the front of the tractor.
The condenser consists of a number of turns of 1
continuous coils mounted in a series of thin cooling
fins to provide maximum heat transfer in a minimum
amount of space.
The condenser receives the hot, high pressure

refrigerant vapor from the compressor. As the hot
vapor passes through the coil, outside air is drawn
around the coils by the engine fan. Heat is
transferred from the hot refrigerant vapor into the
cooler outside air flowing across the coils and fins. 86064003
The refrigerant condenses inside the unit and
becomes a high pressure liquid. 2
EVAPORATOR
The evaporator core, 1, is located in the ventilation
housing located in the cab roof housing. Similar to the
condenser, the evaporator core consists of numer-
ous tubes mounted in a series of thin aluminum
cooling fins. The fins and tubing are designed to
transfer heat from the cab air to the cold refrigerant
liquid as it moves through the evaporator tubing.
The low pressure liquid inside the tubes removes 1

heat from air passing around them. As the refrigerant
absorbs heat, it boils and flashes to a vapor. The low
pressure vapor then flows to the compressor to 86063998
repeat the refrigerant cycle.
3
50-6
EXPANSION VALVE
The thermal expansion valve is on the pressure line
leading from the receiver/drier into the evaporator.
The valve changes the liquid refrigerant from high to 1
low pressure without a change from liquid to vapor.
A thermostatically controlled valve within the
expansion valve body controls the volume of liquid
refrigerant passing through the orifice and makes
sure the refrigerant is fully vaporized within the
evaporator by sensing the amount of superheat of 2
the vapor leaving the evaporator. Liquid refrigerant
would damage the compressor.
20036387
The valve responds to changes in the cooling
requirements of the system. When increased cooling 4
is required, the valve opens to increase the
refrigerant flow. When less cooling is required, the
valve closes and decreases the refrigerant flow. All
of the needed temperature and pressure sensing
functions are consolidated into this unit. No other
external tubes are required for this operation.
When the compressor is off, pressure, (system plus

spring pressure), below the actuating diaphragm, 1,
is greater than the pressure above it. The metering
ball, 2, is held tightly against the seat by the spring,
and no flow is present through the valve.
Upon initial setup of the compressor, the pressure
drops rapidly in area 1. The pressure above the
diaphragm is now greater than that below. The
actuating rod pushes down, unseating the ball and 1
allowing refrigerant to flow to the evaporator. During
operation, the pressure below the diaphragm will
change and adjust valve position to maintain 8°
superheat of the refrigerant flowing from the
evaporator.
20036388
5
• Temperature Sensor, 1
• Ball and Spring, 2 1
• To Evaporator, 3
• From Evaporator, 4
4 5
• To Compressor, 5
• From Condenser, 6
3
6
2
20036386
6
50-7
RECEIVER/DRIER
The receiver/drier, 1, is located at the front of the
tractor.
The receiver/drier receives the high pressure liquid

refrigerant from the condenser through an inlet line.
The dryer section contains a desiccant to absorb

moisture but can only absorb a limited amount of
moisture before reaching a saturation point. The 1
ability to retain moisture absorbed is dependent upon
temperature. As the outside temperature increases,
the ability to retain absorbed moisture decreases. 86064003
This is why an air conditioning system with a
saturated dryer may operate satisfactorily when 7
outside temperatures are low, but stops cooling
when the temperature increases.
The refrigerant exits the receiver/drier through an

outlet connection and flows to the thermostatic
expansion valve.
NOTE: Any moisture in the air conditioning system is

extremely harmful. Moisture not absorbed by the
dryer will circulate with the refrigerant. Droplets may
collect and freeze in the thermostatic expansion
valve restricting refrigerant flow. The moisture
circulating in the system may also react with the
refrigerant to form hydrochloric acid.
NOTE: In general, the receiver/drier should be

replaced any time the system is opened for service.
HEATER
The heater core, 1, is located in the ventilation 1
housing located in the cab roof housing. Similar to the
evaporator, the heater core consists of numerous
tubes in a series of thin aluminum cooling fins. The
fins and tubing are designed to transfer heat from the
heated engine coolant to the cab air as it moves
across the tubing.
86063998
8
50-8
A water valve, 1, is located under an access panel
(not shown) on left side of the cab roof. The valve is
installed to control the flow of hot engine coolant
through the heater core. The valve is controlled with
a cable operated switch located inside the cab. 1
86063999
9
HEATER SYSTEM
The water pump, 1, sends coolant through the
engine block and back through the cylinder head to
the thermostat. The coolant then flows to the heater
core and back to the water pump.
Coolant Flow Chart:

• Thermostat (Out) to Heater Valve
• Heater Valve to Heater Core
• Heater Core (In) to Water Pump
1
• Water Pump to Engine Block
86064535
• Engine Block to Cylinder Head
• Cylinder Head to Thermostat 10
As the coolant reaches operating temperature, turn 86064000

the temperature knob, 1, clockwise to open the
heater valve, 2.
The temperature knob mechanically controls the

opening or closing of the heater valve.
1
NOTE: To increase cab temperature, turn knob, 1, 2
clockwise and to decrease cab temperature, turn
knob, 1, counterclockwise.
86063999
11
50-9
As the hot coolant is flowing through the heater core,
1, the blower motor, 2, is blowing across the heater 1
core coils to produce the hot air coming out of the
vents.
NOTE: The A/C and Heater utilizes the same fans

and vents.
2
86063998
12
HVAC CONTROL PANEL
A three speed switch, 1, controls the blower motor. 3 1 2
The fan speed switch, 1, selects which circuit of the
motor to supply with power. The switch uses a speed
control resistor to change the fan speed. The motor
is wired internally to produce the three different
speeds.
The A/C switch, 2, must be depressed to activate the

air conditioning system. A light will appear when the
switch is activated.
The temperature switch, 3, only controls the water 86064000

valve. The water valve can be opened and closed
with a cable that is positioned between the switch and 13
the water valve.
CAB AIR FILTER

The cab air filter, 1, is located on the right side of the 2
cab roof behind the access grill, 2.
The filter removes pollen and dust from the incoming

air.
1
10054359
14
50-10
Cleaning Cab Air Filter
Clean the air filter if it shows an accumulation of dirt
on the bottom side. Use one the following methods:
Tap the filter gently on a flat surface with the dirty side
down.
Compressed air may be used if the pressure does

not exceed 2.0 bar (30 psi). Keep the nozzle at least
25 mm (1 in) from the filter surface. Direct the air
through the filter, opposite to the air flow through the
filter. Do not direct air against the dirty side of the filter
because it will force dirt further into the pleats.
COMPRESSOR PROTECTION SWITCHES

High-Pressure Cutout Switch
The high-pressure switch, 1, is located in the
receiver/drier outlet line.
1
Excessive refrigerant pressure may occur due to a
faulty expansion valve or icing up of the expansion
valve orifice. Excessive pressure will result in severe
damage to the compressor pump. The purpose of the
high-pressure switch is to shut off the compressor
pump in case of excessive pressure in the refrigerant
system.
86064001
The high pressure switch is factory set and 15
non-adjustable.
Low-Pressure Cutout Switch
The low-pressure switch, 2, shuts off the compressor
pump in the event of excessively low pressure in the
refrigerant system.
The low-pressure switch is on the low pressure line

near the compressor. Loss of refrigerant in the
system will result in insufficient cooling and
continuous operation, which in turn could lead to
possible damage to the compressor pump.
2
86064001
16
50-11
COMPONENT LOCATION
CAB AND ENGINE BAY
8
5
11 6
7
2
12
10
13
14
4
3
66064571
17
1. Heater Control Valve 8. Recirculation Filter
2. A/C Suction Hose 9. HVAC Box (Details located in Cab Roof Figure)
3. Condensate Drain Hose (Right) 10. A/C Compressor
4. Condensate Drain Hose (Left) 11. High Pressure Switch
5. Heater Return Hose 12. Low Pressure Switch
6. Heater Supply Hose 13. Receiver/Drier
7. A/C Liquid Hose 14. Condenser
50-12
CAB ROOF
2
4
7 6
86063998
18
1. Evaporator Core
2. Heater Core
3. Expansion Valve
4. Temperature Probe
5. Blower Fan Resistor
6. Blower Motor Assembly
7. Temperature Switch
50-13
TROUBLESHOOTING
Problem Possible Cause Correction

No Cooling.
g A/C Mode Switch not on. Turn A/C Mode switch on.
Loss of refrigerant. Refer to “Pressure Test” in this sec-
tion.
Insufficient air flow through evaporator. Check air filter.
Check evaporator core and clean as
necessary.
Check blower motor operation. Per-
form electrical checks. Refer to elec-
trical section 55.
Loose or broken compressor drive belt. Check belt and tension. Adjust or re-
place as necessary.
Compressor clutch does not engage. Perform electrical checks. Refer to
electrical section 55.
Faulty expansion valve. Replace Expansion valve.
Faulty compressor and/or compressor Perform electrical checks. Refer to
clutch. electrical section 55.
Insufficient Cooling
g Dirty Evaporator coil and/or filter. Visually inspect. Clean as necessary.
Dirty Condenser core. Visually inspect. Clean as necessary.
Compressor drive belt slipping. Visually inspect. Clean as necessary.
Faulty expansion valve operation. Expansion Valve -- Testing.
Evaporator icing up. Refer to “Pressure Test” in this sec-
tion.
Low refrigerant charge. Refer to “Pressure Test” in this sec-
tion.
Heater Valve leak through. Operate engine at 1500 rpm for 15
minutes to warm engine coolant. Op-
erate the A/C system at maximum
cooling. Install stem thermometer in
mid-cab louver and record tempera-
ture. Close heater core supply valve.
Wait a few minutes and check the
temperature. If the temperature
drops, valve leak through is the prob-
lem; replace heater valve. Refer to
“Heater Valve -- Removal.”
No Heat/Defrost not Heater Core supply and return valves Open Valves.
working. closed.
Coolant not hot. See Engine Cooling section.

Heater Valve Inoperative. Operate engine at 1500 rpm for 15
minutes to warm engine coolant. With
the heater valve open, verify heater
hoses are warm to the touch.
Check the operation of the cable be-
tween the switch and the valve for
proper adjustment. Adjust or replace
as necessary.
50-14
Problem Possible Cause Correction

No air flow/reduced Cab temperature approximately equal to System operating properly.
air flow. temperature set point.
Cab air filter dirty. Clean cab air filter.
Blower motor inoperable. Check blower motor operation. Per-
form electrical checks. Refer to elec-
trical section 55.
Noisy system. Faulty compressor clutch. Replace compressor assembly.
A/C system is inop- Blower speed switch defective. Perform electrical checks. Refer to
erative. electrical section 55.
Compressor oper- No Power and/or ground to blower motor. Perform electrical checks. Refer to
ates, but blower is in- electrical section 55.
operative.
i Defective Blower motor. Replace blower motor.
Blower operates, High pressure switch activated locking out Check High pressure switch opera-
compressor is inop- the clutch. tion. Perform electrical checks. Refer
erative. to electrical section 55.
Low pressure switch activated locking out Check Low pressure switch opera-
the clutch. tion. Perform electrical checks. Refer
to electrical section 55.
Evaporator temperature sensor “freeze” Check temperature sensor operation.
setting reached cycling the clutch OFF. Perform electrical checks. Refer to
Open in switched ground to relay from con- Perform electrical checks. Refer to
troller. electrical section 55.
Power and ground to clutch relay.
Clutch relay defective.

Controller defective. Perform electrical checks. Refer to
50-15
EXPANSION VALVE -- TESTING
No Test Point Expected Result Other Result (Possible Cause)

1 Disconnect Low Pres- Low pressure gauge shows de- Expansion Valve defective. Replace
sure Switch. crease in pressure. as described in “Expansion Valve --
Connect the pressure Go to test 2 Removal” and “Expansion Valve --
test gauge manifold as Installation.”
described in “Overhaul
-- Pressure Test.”
Remove insulation ma-
terial from top of expan-
sion valve.
With engine running
and A/C on maximum
cooling, cool the top of
the expansion valve
with ice.
2 Allow the top of the ex- The valve opens and the pressure If there is little or no change in pres-
pansion valve to warm. rises on the low pressure gauge. sure, replace the expansion valve
as described in “Expansion Valve --
Removal” and “Expansion Valve --
Installation.”
TEMPERATURE/PRESSURE CHART
Ambient % Relative Louver Temps* Normal Low Side Normal High Side
Temperature Humidity °C (°F) Pressure kPa (psi) Pressure kPa (psi)
°C (°F)
Low High Low High Low High Low High
RH RH RH RH RH RH RH RH
21(70) 19 to 21 81 to 89 4 (40) 11(51) 62 to 62 83 to 97 779 to 862 807 to 889
(9 to 9) (12 to 14) (113 to 125) (117 to 129)
27(80) 18 to 20 69 to 77 8(46) 14 (57) 69 to 83 103 to 117 917 to 1014 993 to 1103

(10 to 12) (15 to 17) (133 to 147) (144 to 160)
32 (90) 16 to 18 58 to 64 12 (53) 18 (64) 90 to 103 131 to 145 1089 to 1200 1207 to 1331
(13 to15) (19 to 21) (158 to 174) (175 to 193)
38(100) 14 to 16 48 to 53 16(60) 21(70) 117 to 131 165 to 179 1276 to 1413 1427 to 1579
(17 to 19) (24 to 26) (185 to 205) (207 to 229)
43(110) 12 to 14 36 to 40 19(66) 25(77) 152 to 165 200 to 228 1510 to 1669 1662 to 1841
(22 to 24) (29 to 33) (219 to 242) (241 to 267)
49(120) 10 to 12 26 to 28 23(73) 28(83) 200 to 221 248 to 276 1779 to 1972 1910 to 2117
(29 to 32) (36 to 40) (258 to 286) (277 to 307)
50-16
SERVICE PRECAUTIONARY STATEMENTS essential to ensure that no small, difficult-to-find

leaks go undetected.
Leak Testing
Recharging an air conditioning system that leaks Before leaving a job, make one last leak check.
simply allows more refrigerant to escape into the Catching a leak just after service will save an
atmosphere and ultimately leaves the system inconvenient and expensive return visit.
non-functioning and in need of additional charging.
Refilling
Therefore, the proper service procedure is to locate Refill the air conditioning system using the weight
and fix any leaks before putting any more refrigerant method. The lubricants used in R134a tend to layer
into the system. onto the walls of the refrigeration system. This
If a large amount of refrigerant has leaked out, the layering obscures the view through the sight glass.
system pressure will be too low to identify all but the Visual methods of refilling R134a systems will result
largest leaks. In this case, partially recharge the in improper system charging. For this reason, we do
system with no more than one pound of refrigerant to not recommend the old practice of topping off a
check for leaks. partially discharged air conditioning system using the
sight glass. The DX40 and DX45 uses 1.1 kg (2.4 lbs)
IMPORTANT: of R134a refrigerant.
• Any refrigerant introduced into the system for the

purpose of finding leaks must also be recovered
CONTAMINANTS
without releasing it into the atmosphere. General
• Always use the same type of refrigerant for No mobile air conditioning system can operate for
checking leaks as was originally installed into the long without picking up some contaminants in the
AC system by the manufacturer. refrigerant. The flexible hoses, for example, allow
• Never use compressed air to detect system moisture and air to migrate into the refrigerant from
leaks. The introduction of air into the system may the outside atmosphere. Moisture and non-condens-
create a fire or explosion hazard, may overload able gases (air) are the most common contaminants
the desiccant with moisture, and could contami- found in mobile air conditioning systems.
nate the system with dirt and improper oil.
IMPORTANT: Contaminating R134a with R12 or
All automotive type air conditioning systems leak to CFC will lead to copper plating of steel components
some extent. When servicing them it is important that and major compressor failure.
leakage be minimized. Much of the normal leakage
comes from the slow seepage of refrigerant through Lubricant and refrigerant that remain in service
the flexible hoses. Other common sources of leaks equipment can be contaminants. When you recover
are at joints between the flexible hose and metal a refrigerant, you also will capture a certain amount
tubing or at threaded hose connections. These are of lubricant in the extraction or recovery equipment.
usually much larger leaks than the natural seepage The equipment will drain the lubricant in a catch
through the walls of the hose and are almost always bottle or reservoir for measurement and proper final
repairable. disposal.
Research by the EPA has found that leak detection
can be difficult, but existing halogen leak detection Never use a lubricant that has come out of an air
systems are adequate for the major task of finding conditioning system. Reusing this oil will result in
and repairing leaks causing complaints. Dye stains contamination of the air conditioning system with
are not very satisfactory for finding small leaks. refrigerant, moisture and air from the old oil. Instead,
refill the air conditioning system using fresh oil in the
Newer electronic leak detectors may offer even same amount as that removed during service.
better leak detection capabilities. However, no single Dispose of the used oils in a manner that complies
method can find every leak. Electronic leak detectors with federal, state and local disposal requirements.
may not detect leaks of all refrigerants. For example,
older units designed to detect R12 may not detect To avoid contamination between systems using
R134a. Be sure that the leak detector you use is dissimilar refrigerants, the extraction and recycling
state-of-the-art and that it is designed to detect the equipment MUST be dedicated to a single
refrigerant in the system you are servicing. refrigerant.
Service professionals must be extremely diligent in
their work to correct all possible leaks. Diligence is
50-17
Preventing Mixing of Service Equipment contain contaminants that are different from those in
To help avoid the mistake of charging a system with mobile air conditioning systems. Recovery equip-
an incorrect, incompatible refrigerant, the compres- ment may therefore allow the mixing of different
sor fittings are different for refrigerants R12 and types of refrigerants or introduce contaminants that
R134a. Systems using R134a have quick couple may not be removable by recycling equipment
service connections, while R12 systems use screw available in the service shop.
threads. This prevents the use of the same tools for
different refrigerants, thereby helping to avoid the If you want to remove, clean and reuse R134a
mixing of refrigerants in service equipment. refrigerant, you must use a machine that both
extracts and recycles refrigerant from mobile air
If refrigerants become mixed, the thermodynamic conditioning systems. Dedicate that machine to
and chemical characteristics will change. This R134a only.
change results in excessive pressure and poor
lubrication and leads to failure of the compressor, Recycling equipment meeting SAE standards J1990
desiccant (drier) and other system components. and J2210 is designed to extract and recycle
refrigerants that have been in mobile air conditioning
Ultimately, system failure and an expensive repair bill systems only. R134a refrigerant that also is used in
will result if refrigerants become mixed in a single set non-mobile systems may introduce contaminants to
of service equipment. the refrigerant that equipment meeting SAE J1990
and J2210 cannot remove. This equipment is not
intended for use on non-mobile systems.
REFRIGERANT EXTRACTION AND
RECYCLING EQUIPMENT Using Extraction Equipment
Both extraction and recycling equipment are in use Extraction equipment is relatively small and easily
and available to service technicians. Both types of portable. It is best used if a shop must service
equipment will remove the refrigerant from an air vehicles, such as agricultural or off-highway equip-
conditioning system. However, extraction equipment ment, that cannot easily be brought into the shop. It is
only pulls the refrigerant from the air conditioning also convenient for shops that must deal with a variety
system and stores it in an appropriate container. of different refrigerant types and exchange recovered
Extraction equipment does not clean the refrigerant. refrigerant at some central location.
Its only purpose is to recover the refrigerant from an
air conditioning system prior to disassembling and Always use extraction equipment on those refriger-
servicing it. ants for which it was designed. The lubricants,
hoses, and seals in this equipment have been
Always recycle or reclaim recovered refrigerant designed to work with only one refrigerant.
before putting it back into an air conditioning system.
During service operations involving a partial To help avoid a mix-up of service equipment and
recharge, or while the air conditioning system is in refrigerants, equipment hoses designed for use
use, refrigerant can pick up moisture, lubricants, which each refrigerant are easily identifiable. New
microscopic metal chips, and other potential service hoses used with R134a must have a black
contaminants. In many cases the contaminants stripe along the hose length and carry the
contribute to or are the primary cause of the system designation “SAE J2196/R134a” (hoses labeled
failure. Putting used, unclean refrigerant back into an SAE J 2196” and lacking the black stripe were used
air conditioning system may result in poor system for R12.)
performance.
If you use extraction equipment and send your
NOTE: Reuse of unrecycled, unreclaimed refriger- recovered refrigerant to a reclamation facility,
ant will void the warranty. reclaimed refrigerant you purchase must meet the Air
Conditioning and Refrigeration Institute standards of
Equipment that removes refrigerant from a mobile air purity (ARI Standard 700-88). This will ensure that the
conditioning system (recovery equipment) may allow refrigerant you are using not only meets the purity
you to put the used refrigerant back in the system requirements of SAE J1991 (for R12) OR J2099 (for
without first cleaning it to minimize performance. You R134a), but also that it does not contain incompatible
may also use such conditioning systems. Non-mo- lubricants or other contaminants from non-automotive
bile air conditioning systems use refrigerants and air conditioning systems.
50-18
Using Recycling Equipment WARNING
Recycling equipment extracts and removes common To avoid fire or explosion, do not over-pressurize
contaminants from refrigerants. Recycling equip- R134a. Refrigerant 134a poses a fire and explosion
ment designed and certified to meet SAE standards risk at air concentrations of greater than 60% by
can make refrigerant recovery from mobile air volume. At normal atmospheric pressure and
conditioning systems suitable for reuse in automo- temperature, R134a is nonflammable.
tive air conditioning systems. Like extraction
Do not pressure-test or leak-test R134 service
equipment, SAE standards require that each piece of
equipment or vehicle air conditioning systems
recycling equipment be dedicated to a single
with compressed air. Some mixtures of air and
refrigerant.
R134a are combustible under pressure. These
can result in fire or explosion, causing injury or
NOTE: Only equipment capable of recovering and property damage. Refrigerant and lubricant
cleaning R134a to meet SAE J2099 purity levels manufacturers can provide additional health and
carries a label with the phrase “Design certified by safety information.
Underwriters’ Laboratories, Inc. for compliance with
SAE J2099.
Recovery
The Underwriters’ Laboratories label must be 1. Be sure that all service equipment hose lines
specific that the equipment is “design certified” for have shutoff valves or check valves within 30 cm
the SAE J2099 standard. If not, it certifies only that (12 in) of their ends. This will ensure that only
the machine is free of reasonable shock or other minimal quantities of refrigerant escape to the
electrical hazards to the user. atmosphere when the equipment is discon-
nected from the air conditioning system, and only
Recycling vs. Reclaiming small amounts of moisture and other contami-
Recycled refrigerant has been recovered from a nants can enter the system.
mobile air conditioning system and is cleaned by the
2. Be sure that all equipment, including the
same shop that recovered it to meet J2099 for
connecting hose lines and manifold, are
R134a. The equipment designed to recycle
compatible with the refrigerant in the system with
refrigerant in the shop environment removes only
which you are going to work, and that your
contaminants picked up during the operation of a
equipment has previously been used only with
mobile air conditioning system.
the refrigerant you are about to service.
Refrigerant that is either properly recycled or 3. Be sure that all shutoff valves are tight before
reclaimed is adequate for use in mobile air connecting them to the air conditioning system.
conditioning systems.
CAUTION
CONTAINMENT OF AIR CONDITIONING Keep shutoff valves closed at all times unless
REFRIGERANTS they are connected to a vehicle’s air conditioning
The following procedure is a guide to servicing system, a refrigerant storage container or
mobile air conditioning systems in a way that another piece of service equipment containing
minimizes the potential for losing refrigerant to the the same refrigerant. This prevents refrigerant
atmosphere. Following the procedures in this section from escaping into the atmosphere, damaging
will help ensure compliance with SAE J2211 for the environment, contaminating the equipment,
R134a systems. and costing you money.
50-19
4. Connect the extraction or recovery equipment to WARNING
the air conditioning system in accordance with
Do not flush with compressed air. Some mixtures
the instructions supplied by the equipment
of air and R134a systems could result in fire or
manufacturer.
explosion. Air from a shop compressor also
5. Start the recovery process by turning on the contains moisture, which would contaminate the
extraction equipment and extracting the refriger- system.
ant from the air conditioning system in
accordance with the equipment manufacturer’s IMPORTANT: Never use CFC11, R11, CFC12, R12,
instructions. CFC113, R13 or any other substance to flush an
6. Continue to extract refrigerant until the air R134a system. To do so would break down the
conditioning system is under a vacuum and there lubricant and cause system corrosion.
is no refrigerant remaining in the vehicle system.
Use of other flushing solvents may cause other
7. Verify that there is no refrigerant remaining in the problems. If a vacuum pump does not remove the
system by: solvent, it could affect the chemical stability of the
a) Shutting off the extraction unit and observing refrigerant and lubricant.
the system pressure level.
Recharging/Refilling
b) Waiting five minutes and observing the
Recharge the system only with the proper virgin
system pressure again. If the system
refrigerant or recycled refrigerant purified to meet
pressure has not risen above atmospheric
SAE purity standard (J2099 for R134a). Use the
pressure (0 gauge pressure), all refrigerant
weight method to determine the proper amount of
has been removed and you may proceed to
refrigerant. The DX40 and DX45 uses 1.1 kg (2.4 lbs)
step 8.
of R134a refrigerant.
If after five minutes, the system pressure
reading has risen above atmospheric Using a Manifold Gauge Set
pressure (0 gauge pressure), the extraction/ When using a manifold gauge set to diagnose,
recovery process must be repeated until the recharge, or service the tractor air conditioning
pressure reading remains at or below system:
atmospheric for at least two minutes with the
extraction equipment shut off before pro- 1. Be sure that all equipment hose lines are fitted
ceeding to step 8. with shutoff valves or check valves within 30 cm
8. Close the shutoff valve in the service lines. (12″) of their ends and that the valves are closed.
This will ensure that only minimal quantities of
9. Remove the service lines from the vehicle
refrigerants escape to the atmosphere, and that
system. If the recovery equipment has automatic
only small amounts of moisture and other
closing shutoff valves, verify that they are
contaminants can enter the system.
operating properly and do not leak.
2. Be sure that all equipment including the
10. Determine the amount of lubricant removed from
connecting hose lines and manifolds are:
the air conditioning system during the refrigerant
extraction process. Replenish the air condition- -- Compatible with the refrigerant in the air
ing system with an equal volume of new, correct conditioning system;
lubricant. -- Free of all contaminants;
11. The system is now ready for service or repair. -- Used only for the same type of refrigerant in
the system.
Flushing 3. Be certain that all shutoff valves are closed tightly
Do not flush this system. In the event of a major before connecting them to the air conditioning
compressor failure, replace the compressor output system or charging source.
pressure line and receiver/drier to collect most of the 4. Connect the manifold gauge set to the unit
debris. according to the instructions supplied by the
gauge manufacturer.
50-20
5. Perform the desired diagnostic and service 4. Compare the pressure in the container with the
operation. pressure shown for the temperature of the tank
for R134a. If the pressure in the container is
6. Close the shutoff valves on the service hoses.
equal to or less than the pressure in the table, the
7. Disconnect the hoses from the system. refrigerant in the container meets the require-
ments for excess air.
NOTE: Attach the hoses to recovery or recycling
equipment whenever disconnecting the manifold If the pressure is greater than shown in the table,
gauge set from the air conditioning system, emptying you may still be able to use the refrigerant by
refrigerant from it, or moving the center hose to proceeding to step 5.
another device which cannot accept refrigerant 5. If the pressure exceeds that of the table, connect
pressure. Remove the refrigerant, lubricant, and the tank to recovery or recycling equipment in
contaminants from the hoses. such a way as to allow you to continue to monitor
tank pressure.
Checking Refrigerant for Excess Air
6. Bleed a small amount of vapor from the tank into
At times you may question whether or not a container the recovery or recycling equipment until the tank
of refrigerant has been recycled. One check which pressure is below that shown in the table for the
can be done in the shop is to determine if there is temperature at which the tank was stored. Close
excess air mixed in with the refrigerant. This check is the shutoff valves in the recovery/recycling
a simple comparison of the container pressure with equipment service hose.
theoretical pressure at a known temperature. If the
pressure is equal to or less than a theoretical value NOTE: This process may cause the temperature of
of usable purity established for R134a, the container the tank to drop.
does not have excess air.
7. Allow the tank temperature to restabilize at the
IMPORTANT: Using R134a with excess air will result temperature of the storage room by shaking it
in higher system operating pressures and may cause and allowing it to sit in the same spot for up to
damage to the air conditioning system. another 12 hours.
8. After making certain that container temperature
Do this check in the following manner:
has again stabilized to room temperature, repeat
step 4 above.
1. Store the container for at least 12 hours at a
known temperature of 18.3° C (65° F) or higher. If the pressure exceeds that in the table for the
The container must not be in direct sunlight or storage temperature you measured, the refrigerant
under the influence of any other direct source of in the tank has too much excess air to be used and
heat. must be recycled or reclaimed.
Carry out all of the next steps in the same area
in which the container is stored, as it is very If the refrigerant being checked has been contami-
important that the temperature of the container nated with other refrigerant such as R12, the tank
remain stable. pressure may indicate it contains air. If the tank is
vented and the pressures still indicates a high
2. Attach an appropriate pressure gauge to the reading and you think there is a possibility of the
container. This pressure gauge should read in R134a refrigerant being contaminated with R12, the
increments of 6.9 kPa (1 psi). container must be sent to a reclaim facility.
3. Use a calibrated thermometer to measure the air
temperature within 10 cm (4 in) of the container
surface.
50-21
Containers for Storing Recycled Refrigerant APPLICABLE SAE STANDARDS
Recycled refrigerant must be stored in DOT CFR J639 Safety and containment of refrigerant for
Title 49 or UL containers approved for such use. The mechanical vapor compression systems
container must be specifically marked for the used for mobile air conditioning systems
refrigerant type you are storing. The use of unmarked
containers can lead to mixing of refrigerants and J1989 Recommended service procedure for the
consequent air conditioning system failure. containment of R12
Disposable refrigerant containers should not be used J1991 Standard of purity for use in mobile air
for the storage or recovery of used or recycled conditioning systems
refrigerant. Disposable container are the type of
container in which virgin refrigerant is often sold. J2099 Standard of purity for recycled R134a for use
in a mobile air conditioning system
Any container of recycled refrigerant that has been
stored or transferred must be checked prior to its use J2196 Service hose for automotive air conditioning
in accordance with the temperature /pressure check
described previously in “Checking Refrigerant for J2197 R134a service hose fittings for automotive air
Excess Air.” conditioning service equipment
New storage tanks must be evacuated to at least J2211 Recommended service procedure for the
635 mm (25 in) of mercury prior to use. Otherwise, containment of R134a
excess air may be introduced to the refrigerant.
J2219 Mobile Air Conditioning Industry Criteria and
Guidelines
Disposal of Empty or Near-Empty Disposable
Containers
Related SAE Standards:
Improper scrapping of a disposable container can
release some refrigerant into the atmosphere. This J1990 Extraction and recycle equipment for mobile
must be avoided by removing any of the remaining air conditioning systems
contents with a recovery or recycling machine as
J2209 R12 extraction equipment for mobile air
follows:
conditioning systems
1. Attach the service hose of your recovery or J2210 R134a recycling equipment for mobile air
recycling machine to the container. conditioning systems
2. Open the container valve and the recovery/re-
cycling equipment shutoff valve and evacuate These and other SAE standards may be obtained
the container just as you would a mobile air from
conditioning system.
SAE Customer Service
3. When the maximum stable vacuum has been 400 Commonwealth Drive
achieved, close the container valve and the Warrendale, PA 15096-0001
service hoses valve, allowing the vacuum to be
in the container.
4. Mark the container “empty” and dispose of it
properly.
50-22
MANIFOLD GAUGES AND INTERPRETATIONS

PERFORMANCE TEST EXAMPLES
EXAMPLE 1
Symptoms
1. Evaporator air is lukewarm.
2. Low side pressure is too low. The gauge should
1
read 0.21 -- 2.1 bar (3 -- 30 psi).
3. High side pressure is too low. See the
pressure-temperature chart for correct gauge
readings.
DIAGNOSIS: System refrigerant is low. A small
leak may cause this. 19
Corrective Procedures
Ambient High Pressure High-Pressure
1. Leak test the system. Temperature* Gauge Gauge
2. Extract the refrigerant from the system. Reading Reading
3. Repair the leaks. Replace any faulty lines or °C °F bar psi

components. 21 70 7.9 -- 9.2 114 -- 134
4. Check compressor oil and add oil if necessary.
24 75 8.7 -- 10.1 126 -- 146
5. Evacuate the system.
26 80 9.7 -- 11.1 141 -- 161
6. Charge the system.
29.5 85 11 -- 12.4 159 -- 179
7. Performance test the system.
32 90 11.6 -- 13 168 -- 188
*NOTE: Test procedure based upon ambient
temperature of 35°C (95°F). For proper high side 35 95 12.5 -- 13.9 181 -- 201
gauge reading for other ambient temperatures, refer 38 100 13.9 -- 15.2 201 -- 221
to the pressure-temperature chart.
40.5 105 15 -- 16.4 218 -- 238
43 110 17 -- 18.4 246 -- 266
46 115 19.1 -- 20.5 277 -- 297
49 120 21.2 -- 22.6 307 -- 327
50-23
EXAMPLE 2
SYMPTOMS
1. Evaporator air is warm.
2. Low side pressure is very low. The gauge should
read 0.21 -- 2.1 bar (3 -- 30 psi).
pressure-temperature chart for the correct
gauge readings.
DIAGNOSIS: System refrigerant is extremely low.
A serious leak is indicated.
CORRECTIVE PROCEDURES 20
1. Leak test the system.
2. Extract the refrigerant from the system. Ambient High Pressure High-Pressure
Temperature* Gauge Gauge
3. Repair leaks. Reading Reading
4. Check compressor oil to ensure no loss. °C °F bar psi
5. Evacuate the system. 21 70 7.9 -- 9.2 114 -- 134
6. Charge the system. 24 75 8.7 -- 10.1 126 -- 146
7. Performance test the system. 26 80 9.7 -- 11.1 141 -- 161
*NOTE: Test procedure based upon ambient 29.5 85 11 -- 12.4 159 -- 179
temperature of 35°C (95°F). For proper high side
gauge reading for other ambient temperatures, refer 32 90 11.6 -- 13 168 -- 188
35 95 12.5 -- 13.9 181 -- 201
38 100 13.9 -- 15.2 201 -- 221
40.5 105 15 -- 16.4 218 -- 238
43 110 17 -- 18.4 246 -- 266

46 115 19.1 -- 20.5 277 -- 297
49 120 21.2 -- 22.6 307 -- 327
50-24
EXAMPLE 3
SYMPTOMS
1. Evaporator air is not being cooled.
2. Low side pressure reading does not change
when compressor cycles on and off. 4
3. High side pressure slightly high or slightly low.
See charts the pressure-temperature chart for
correct gauge readings.
DIAGNOSIS: Non-condensables (air or moisture)
are present. System not fully charged.
CORRECTIVE PROCEDURES 21
1. Leak test the system. Give special attention to
the compressor seal area. Ambient High Pressure High-Pressure
2. Extract the refrigerant from the system. Temperature* Gauge Gauge
Reading Reading
3. Repair any leaks.
°C °F bar psi
4. Replace the receiver/drier.
21 70 7.9 -- 9.2 114 -- 134
5. Check the compressor oil to ensure no loss.
24 75 8.7 -- 10.1 126 -- 146
26 80 9.7 -- 11.1 141 -- 161
29.5 85 11 -- 12.4 159 -- 179
32 90 11.6 -- 13 168 -- 188
gauge reading for other ambient temperatures, refer
38 100 13.9 -- 15.2 201 -- 221
40.5 105 15 -- 16.4 218 -- 238
43 110 17 -- 18.4 246 -- 266

46 115 19.1 -- 20.5 277 -- 297
49 120 21.2 -- 22.6 307 -- 327
50-25
EXAMPLE 4
SYMPTOMS
1. Evaporator air is not being cooled.
2. Low side pressure is too high. The gauge should
read 0.21 -- 2.1 bar (3 -- 30 psi). 40
gauge readings.
4. System is fully charged.
DIAGNOSIS: Internal leak in compressor caused
by worn or scored pistons, rings, or cylinders. 22
CORRECTIVE PROCEDURE
Replace the compressor. Ambient High Pressure High-Pressure
*NOTE: Test procedure based upon ambient Reading Reading
temperature of 35°C (95°F). For proper high side °C °F bar psi
to the pressure-temperature chart. 21 70 7.9 -- 9.2 114 -- 134
24 75 8.7 -- 10.1 126 -- 146
26 80 9.7 -- 11.1 141 -- 161

29.5 85 11 -- 12.4 159 -- 179
32 90 11.6 -- 13 168 -- 188
35 95 12.5 -- 13.9 181 -- 201

38 100 13.9 -- 15.2 201 -- 221
40.5 105 15 -- 16.4 218 -- 238
43 110 17 -- 18.4 246 -- 266

46 115 19.1 -- 20.5 277 -- 297
49 120 21.2 -- 22.6 307 -- 327
50-26
EXAMPLE 5
SYMPTOMS 40
1. Insufficient or no cooling. Engine overheats in
some cases.
read 0.21 -- 2.1 bar (3 -- 30 psi).
3. High side pressure is too high. See the
gauge readings.
4. Liquid line is hot.
DIAGNOSIS: The system pressure is too high on 23
the high side due to improper operation of
condenser. Refrigerant charge may be normal or
excessive. Ambient High Pressure High-Pressure
CORRECTIVE PROCEDURES Reading Reading
1. Check belt tension. Loose or worn drive belts °C °F bar psi
could cause excessive pressures in the
compressor head. 21 70 7.9 -- 9.2 114 -- 134
2. Look for clogged passages between the 24 75 8.7 -- 10.1 126 -- 146
condenser fins and coil or other obstructions that 26 80 9.7 -- 11.1 141 -- 161
could reduce condenser airflow.
29.5 85 11 -- 12.4 159 -- 179
3. If engine overheats, inspect the radiator fan and
pressure cap for proper operation. 32 90 11.6 -- 13 168 -- 188
Run the system and check performance. If it still 35 95 12.5 -- 13.9 181 -- 201
is unsatisfactory, proceed as follows.
38 100 13.9 -- 15.2 201 -- 221
4. Check for refrigerant overcharge and correct as
follows: 40.5 105 15 -- 16.4 218 -- 238
a. Extract the refrigerant. 43 110 17 -- 18.4 246 -- 266

b. Add new refrigerant. 46 115 19.1 -- 20.5 277 -- 297
Operate the system and recheck the perfor-
49 120 21.2 -- 22.6 307 -- 327
mance. If the gauge readings are still too high,
proceed as follows.
5. Extract the refrigerant from the system.
6. Remove the condenser. If it appears to be dirty
or plugged, replace it.
7. Replace the receiver/drier.
8. Evacuate the system, and recharge it.
50-27
EXAMPLE 6
SYMPTOMS
1. Cooling is insufficient during the hottest part of
hot days. 10
2. The low side pressure reading is normal 0.21 --
2.1 bar (3 -- 30 psi), but drops to a vacuum during
testing.
3. The high side pressure reading is normal but
drops when the low side reading shows a
vacuum.
4. Evaporator air is sufficiently cold until the low
side pressure gauge shows a vacuum; then it 24
becomes warm.
DIAGNOSIS: Excessive moisture is in system. Ambient High Pressure High-Pressure
Drying agent in receiver/drier is saturated and Temperature* Gauge Gauge
releases moisture during high outside air temps. Reading Reading
This moisture collects and freezes in the
°C °F bar psi
expansion valve, preventing a flow of refrigerant
through the evaporator. 21 70 7.9 -- 9.2 114 -- 134
CORRECTIVE PROCEDURES 24 75 8.7 -- 10.1 126 -- 146
1. Extract the refrigerant from the system. 26 80 9.7 -- 11.1 141 -- 161
2. Replace the receiver/drier. 29.5 85 11 -- 12.4 159 -- 179
3. Evacuate the system. 32 90 11.6 -- 13 168 -- 188

5. Performance test the system. 38 100 13.9 -- 15.2 201 -- 221
*NOTE: Test procedure based upon ambient 40.5 105 15 -- 16.4 218 -- 238
gauge reading for other ambient temperatures, refer 43 110 17 -- 18.4 246 -- 266
49 120 21.2 -- 22.6 307 -- 327
50-28
EXAMPLE 7
SYMPTOMS
40
1. Insufficient or no cooling.
read 0.21 -- 2.1 bar (3 -- 30 psi).
gauge readings.
DIAGNOSIS: Air in system. This, and the
moisture in the air, contaminates the refrigerant,
causing the system to malfunction.
25
CORRECTIVE PROCEDURES
1. Extract the refrigerant from the system. Ambient High Pressure High-Pressure
2. Replace the receiver/drier. Temperature* Gauge Gauge
Reading Reading
°C °F bar psi
21 70 7.9 -- 9.2 114 -- 134
24 75 8.7 -- 10.1 126 -- 146
gauge reading for other ambient temperatures, refer 29.5 85 11 -- 12.4 159 -- 179
32 90 11.6 -- 13 168 -- 188
35 95 12.5 -- 13.9 181 -- 201

38 100 13.9 -- 15.2 201 -- 221
40.5 105 15 -- 16.4 218 -- 238
43 110 17 -- 18.4 246 -- 266

46 115 19.1 -- 20.5 277 -- 297
49 120 21.2 -- 22.6 307 -- 327
50-29
EXAMPLE 8
SYMPTOMS
40
1. Insufficient or no cooling.
read 21 -- 207 kPa (3 -- 30 psi).
pressure-temperature chart for correct gauge
readings.
4. Evaporator and suction hose (to compressor)
surfaces show considerable moisture.
DIAGNOSIS: Thermostatic expansion valve is 26
allowing too much refrigerant to flow through the
evaporator coils. The valve may be stuck open,
or the temperature sensing bulb may be Ambient High Pressure High-Pressure
incorrectly mounted. Temperature* Gauge Gauge
Reading Reading
CORRECTIVE PROCEDURES °C °F bar psi
1. Check for a sticking expansion valve: 21 70 7.9 -- 9.2 114 -- 134
a. Operate the system at maximum cooling. 24 75 8.7 -- 10.1 126 -- 146
b. Check the low side gauge. The pressure 26 80 9.7 -- 11.1 141 -- 161
should drop slowly.
2. If the test indicates that the expansion valve is 29.5 85 11 -- 12.4 159 -- 179
defective, proceed as follows: 32 90 11.6 -- 13 168 -- 188
a. Extract the refrigerant from the system. 35 95 12.5 -- 13.9 181 -- 201
b. Replace the expansion valve.
38 100 13.9 -- 15.2 201 -- 221
c. Evacuate the system.
d. Charge the system. 40.5 105 15 -- 16.4 218 -- 238
e. Performance test the system. 43 110 17 -- 18.4 246 -- 266
*NOTE: Test procedure based upon ambient 46 115 19.1 -- 20.5 277 -- 297
50-30
EXAMPLE 9
SYMPTOMS
1. Evaporator air is cool, but not sufficiently cold.
2. Low side pressure is too low (0 or vacuum). The
gauge should read 0.21 -- 2.1 bar (3 -- 30 psi).
3. High side pressure is low. See the pressure-tem-
perature chart for the correct gauge readings.
4. The surface of the evaporator valve inlet pipe
shows considerable moisture or frost.
DIAGNOSIS: Expansion valve is not permitting a
sufficient flow of refrigerant. Possible causes 27
include a valve stuck in restricted or closed
position, or too little refrigerant in temperature
sensing bulb. Ambient High Pressure High-Pressure
1. Place a finger on the expansion valve inlet. If the °C °F bar psi
inlet is too cold to keep your finger on it, proceed
as follows: 21 70 7.9 -- 9.2 114 -- 134
a. Operate the system at maximum cooling. 24 75 8.7 -- 10.1 126 -- 146

b. Check the low side gauge. The pressure 26 80 9.7 -- 11.1 141 -- 161
should drop slowly.
29.5 85 11 -- 12.4 159 -- 179
2. If the expansion valve inlet surface shows frost or
heavy moisture, proceed as follows: 32 90 11.6 -- 13 168 -- 188
a. Extract the refrigerant from the system. 35 95 12.5 -- 13.9 181 -- 201
b. Clear blockage at inlet line to expansion 38 100 13.9 -- 15.2 201 -- 221
valve.
40.5 105 15 -- 16.4 218 -- 238
3. If the corrective procedure outlined in Step 1
shows that the expansion valve is defective, 43 110 17 -- 18.4 246 -- 266
proceed as follows:
46 115 19.1 -- 20.5 277 -- 297
a. Evacuate the system.
49 120 21.2 -- 22.6 307 -- 327
b. Charge the system.
c. Performance test the system.
50-31
EXAMPLE 10
SYMPTOMS
1. Evaporator is only slightly cool.
2. Liquid line and receiver/drier are cool to touch
and show frost or considerable moisture. 0
3. Low side pressure is too low. The gauge should
read 0.21 -- 2.1 bar (3 -- 30 psi).
gauge readings.
NOTE: A normal or high reading of the high side 28
pressure gauge under these conditions indicates
that the system is overcharged or that the condenser
or receiver/drier is too small. Ambient High Pressure High-Pressure
DIAGNOSIS: Restriction in the liquid line and/or Reading Reading
receiver/drier resulting in a “starved” evaporator °C °F bar psi
(compressor moving refrigerant from the evapo-
rator faster than it can enter). 21 70 7.9 -- 9.2 114 -- 134
CORRECTIVE PROCEDURES 24 75 8.7 -- 10.1 126 -- 146
1. Extract the refrigerant from the system. 26 80 9.7 -- 11.1 141 -- 161
2. Replace the liquid lines, receiver/drier, or other 29.5 85 11 -- 12.4 159 -- 179
obstructed components. 32 90 11.6 -- 13 168 -- 188
3. Evacuate the system. 35 95 12.5 -- 13.9 181 -- 201
40.5 105 15 -- 16.4 218 -- 238
43 110 17 -- 18.4 246 -- 266
49 120 21.2 -- 22.6 307 -- 327
50-32
EXAMPLE 11
SYMPTOMS
1. Compressor cycles (cuts in and out) too rapidly.
29
2. Low side pressure readings are too high, during
on and off compressor cycles and between
cycles. The readings should be:
a. 20.7 -- 103.4 kPa (3 --15 psi) -- cycle on
b. 248.2 -- 268.9 kPa (36 -- 39 psi) -- cycle off
c. 165.5 -- 193.1 kPa (24 -- 28 psi) -- between
cycles
3. High side pressure is normal. See the
pressure-temperature chart for the correct 29
gauge readings.
DIAGNOSIS: Defective thermostatic switch. Ambient High Pressure High-Pressure
1. Stop the engine and shut off air conditioning °C °F bar psi
system.
21 70 7.9 -- 9.2 114 -- 134
2. Replace thermostatic switch.
24 75 8.7 -- 10.1 126 -- 146
3. Install the switch’s temperature sensing line in
26 80 9.7 -- 11.1 141 -- 161
the same position and depth (in the evaporator
core) as previous bulb. 29.5 85 11 -- 12.4 159 -- 179
CAUTION 32 90 11.6 -- 13 168 -- 188

The line is filled with refrigerant under pressure. 35 95 12.5 -- 13.9 181 -- 201
Do not kink or bend it too sharply.
38 100 13.9 -- 15.2 201 -- 221
4. Performance test the system. 40.5 105 15 -- 16.4 218 -- 238
*NOTE: Test procedure based upon ambient 43 110 17 -- 18.4 246 -- 266
50-33
EVACUATING THE REFRIGERANT

1. Recovered refrigerant passes through an oil
separator and filter-drier before entering the
refrigerant tank. The moisture indicator will turn
green when dry refrigerant passes over it.
1
2. If possible, run the air conditioning system for ten
minutes before starting the recovery process.
Turn the system off before proceeding.
3. Clean the external surfaces of the compressor
and hoses. Remove the caps from the service
ports, 1, on the suction and pressure hoses.
86064001
30
4. Make sure the charging station manifold gauge
valves are in the closed position. Connect the
hose from the low pressure gauge to the port on
the suction hose. Connect the hose from the high
pressure gauge to the port on the discharge
hose. Turn in both thumbscrews to depress the
service valves.
5. Open the high and low valves.
86060848
31
6. Make certain the refrigerant tank gas and liquid
valves are open.
86060842
32
50-34
7. Connect the main power plug to a 115 volt AC
outlet. Move the main power switch to the ON
position and depress the recovery start switch.
The compressor will shut OFF automatically
when recovery is complete.
8. Wait five minutes and observe the manifold
pressure gauges for a pressure rise. If pressure
rises above zero psi, depress the hold/cont
switch. Then wait for the compressor to
automatically shut OFF.
86060846
33
9. Drain the oil separator of the A/C system oil.
Open the air purge valve long enough to let some
of the compressor discharge pressure back into
the separator.
86060843
34
10. Slowly open the oil drain valve and drain the oil
into the reservoir. When the oil stops draining,
close the oil drain valve completely.
86060844
35
50-35
11. Fill the A/C compressor with fresh SP-20 PAG oil
equal to the amount in the reservoir.
86060845
36
12. Disconnect the hoses from the service ports, 1
and install the caps.
86064001
37
13. Replace the receiver/drier, 1, if one or more of the
following conditions occurs before you remove
the air and moisture from the system:
• The system has been open for service
before. 1
• Receiver/drier has operated two or more
years.
• Disassembly of compressor shows small
particles of moisture removing material (gold
or brown particles).
• Large system leak (broken hose or break in
a line). 86064003
• Too much air or moisture in system. 38
• Removal of compressor caused the system
to be opened (uncapped) longer than 5
minutes.
50-36
VACUUM TEST
1. Make sure the charging station manifold gauge
valves are in the closed position. Connect the
hose from the low pressure gauge to the port on 2
the suction hose, 1. Connect the hose from the
high pressure gauge to the port on the discharge 1
hose, 2. Turn both thumbscrews to depress the
service valves.
2. Removal of air and moisture from the system is
necessary after the refrigerant has been
removed from the system after the system has
been opened for maintenance. Air enters the
system when the system is opened air has
moisture that must be removed to prevent 86064001
damage to the system components. 39
3. Air and moisture are removed from the system by
a vacuum pump. A vacuum pump is on the only
equipment made that will lower the pressure in a
system enough to change the moisture to a vapor
so that the moisture can be removed.
NOTE: Refer to the vacuum pump manufacture’s
user manual for additional information.
4. Connect the main power plug to a 115 volt AC
outlet. Move the main power switch to the ON
position. If the program and vacuum do not
appear at the top of the display, press the
vacuum key. Program a minimum of 45 minutes
and press the Enter Key. The display will flash
once indicating the programmed data has been
accepted.
86060847
40
5. Press the Charge Key. Program and Charge will
appear on the display.
86060849
41
50-37
6. Program 1.1 kg (2.40 lbs) and press the enter
key. The display will flash once indicating the
programmed data has been accepted.
86060847
42
7. Full open the low and high pressure valves.
86060849
43
8. Open the red (vapor) and blue (liquid) valves on
the tank.
9. Press the Vacuum key. Automatic will show on
the display and after a slight delay, the vacuum
pump will start. The display will show the amount
of time programmed and begin a countdown to
zero.
86060849
44
50-38
10. When the programmed time has elapsed, an
automatic hold occurs. Check the low pressure
gauge to see that the A/C system maintains a 28
-- 29-1/2 in of mercury (Hg). The low pressure
gauge must not increase faster than one inch of
mercury (Hg) in 15 minutes. If the system will not
hold vacuum, a leak exist that must be corrected
before recharging can begin. See “Leakage Test”
for a leak test.
86060847
45
50-39
PRESSURE TEST
NOTE: The compressor casing is stamped with a “D”
and “S” to indicate the discharge and suction ports.
1. Connect the pressure test gauge manifold to the 1

test connections at the compressor. Connect the
high side hose to the discharge side, 1, and low 2
side hose to the suction side, 2.
86064001
46
2. On the pressure test gauge manifold, close the
high side valve, 1, and the low side valve, 2.
3. Close the cab windows and doors and set the
parking brake.
4. Start the engine and run at fast idle speed
(approximately 1500 rpm). 1
2
5. Set A/C mode switch to “ON”.
6. Operate the system at maximum cooling with the
blower fan at high speed for 10 minutes to
stabilize all components.
7. Check the manifold high and low pressure 26060841
gauges and compare the reading to the pressure 47
indicated on the air conditioning temperature/
pressure chart. Refer to “Manifold Gauges and
interpretations” and “Temperature/Pressure
Chart.”
50-40
LEAKAGE TEST
1. Shut off the engine.
WARNING
When refrigerant comes in contact with an open
flame, it forms phosgene gas. Never breathe
these fumes.
2. Use electronic leak detector OEM1437 to inspect

all connections. Use instructions from manufac-
turer of leak finding tool.
NOTE: To properly check the expansion valve for
leaks, remove the insulation tape.
3. Check Compressor oil level. Refill as necessary.

4. Repair all leaks and recharge the system.
CHARGING
1. Press the charge key to begin refrigerant
charging. Automatic and Charge will appear on
the display. The display shows the programmed
amount and counts down to zero as charging
proceeds. When charging is completed, the
display shows CPL.
86060847
48
2. Completely close the high and low pressure
manifold valves.
3. Start the engine and run at 1500 rpm. Operate
the air conditioning system at maximum cooling
setting and blower speed with the doors and
windows open.
NOTE: The compressor will not operate if the system
pressure is too low or too high. If the compressor fails
to operate and the condenser blowers also fail to
operate when you actuate the A/C switch, check the
system pressure to determine if refrigerant is
present. Check for continuity at the pressure
86060848
switches and the temperature switch located at the
evaporator. 49
50-41
4. Observe the pressure gauge readings to
determine that the correct amount of refrigerant
has entered the system. See chart on
temperature and pressure variations.
IMPORTANT: Check the OEM equipment manual
before performing this step to avoid damaging
recovery unit. Pressure reading should be obtainable
with valves closed. Damage may occur if machine is
started the valves accidentally open or if either or
both valves are open while the A/C system operating.
86060850
50
5. Stop the engine, close any open valves and
carefully remove the manifold gauge hoses.
6. Install the caps on the suction service port, 1 and 2
the discharge service port, 2.
1
86064001
51
50-42
OVERHAUL
BELT REPLACEMENT
1. Loosen pulley bolt, 1, to allow pulley movement.
2. Loosen jam nut, 2 and turn bolt, 3, clockwise to
tighten the belt and counterclockwise to loosen
the belt.
2 1
3. Remove the belt, 4, from the pulleys and replace
as needed.
4. Install new belt onto pulleys and secure 3
according to specifications.
Specification
86064002
• Belt Tension -- 317± 11 N (71.3± 2.5 lbf)
52
• Belt Deflection Force -- 25± 0.5 N (5.6± 0.11 lbf)
• Belt Deflection -- 7 mm (0.28 in)
HVAC CONTROLS
Removal
1. Remove the six screws, 1, securing the HVAC
panel to the roof.
1
86064000
53
2. Remove the knob, 1, to switch being replaced by
prying/pulling it outward. 3
3. Remove the nut, 2, securing the switch, 3, to the
cover.
1
66064012
54
50-43
Installation
1. Install new switch, 1 and secure with nut, 2. 1
Install knob, 3.
3
66064012
55
2. Install the six screws, 1, securing the HVAC
panel to the roof.
1
86064000
56
HEATER VALVE
Removal
1. Remove the cover on the left side of the cab, (not 1
shown). Drain the coolant from the system.
2. Remove the hose clamps, 1. 1
3. Remove the hoses from both sides of the heater
valve, 2. 2
4. Disconnect the cable from the valve, (not
shown). Remove valve from the roof.
86063999
57
50-44
Installation
1. Install the heater valve, 1, into cab roof and
attach the heater switch cable to the valve. 2
2. Attach the heater hoses to both sides of the valve
and secure with the hoses clamps, 2, from
removal.
2
86063999
58
CONDENSER
Removal 1
IMPORTANT: This component can only be removed
after the entire system has been discharged using an
appropriate recovery system.
IMPORTANT: When the system is open for service,

it is required that the receiver/drier be replaced as
well to avoid future complication.
1. Disconnect the A/C line, 1, going into the

condenser from the receiver/drier. 86064004
IMPORTANT: Cap off the lines to keep moisture and 59
debris from entering the system.
2. Remove the hardware, 1, that secures the
coolant bottle and receiver/drier bracket to the
condenser.
3. Remove the coolant bottle and receiver/drier
bracket assembly.
86063996
60
50-45
4. Remove the air dam, 1.
86064003
61
5. Remove the high pressure hose, 1, going in the
top of the condenser.
IMPORTANT: Cap off the lines to keep moisture and 1
86064005
62
6. Loosen the lower wing nuts, 1.
86064004
63
50-46
7. Remove the upper hair pins, 1.
86064005
64
8. Remove the condenser, 1, from the mounting.
9. Replace the receiver/drier as described in this
section.
86064003
65
Installation
1. Install the condenser, 1, into the mounting.
86064003
66
50-47
2. Secure the lower wing nuts, 1.
86064004
67
3. Install the upper hair pins, 1.
4. Install a new O-ring onto line. Lubricate the
O-ring with PAG 20 A/C oil before attaching the 1 2
line.
5. Attach the A/C line, 2, onto the condenser.
86064005
68
6. Install the coolant bottle and receiver/drier
bracket assembly.
7. Install the hardware, 1, that secures the coolant
bottle and receiver/drier bracket to the condens-
er.
86063996
69
50-48
8. Install a new O-ring onto line. Lubricate the
O-ring with PAG 20 A/C oil before attaching the
line. 1
9. Attach the A/C line, 1, onto the condenser.
86064004
70
10. Install the air dam, 1.
11. Perform a vacuum test and after all checks are
complete, fill the system. Refer to the “Vacuum
Test” and “Charging” in this section. 1
86064003
71
RECEIVER/DRIER
2
Removal 1
1. Loosen and remove coupler, 1, at receiver/drier.
2. Loosen and remove the high pressure hose, 2, at
the receiver/drier. 4
3. Remove hardware, 3 and brace securing the 3
receiver/drier to the bracket. 86064003
4. Remove the receiver/drier, 4. 72
IMPORTANT: Cap off the lines to keep moisture and

50-49
Installation
1. Install a new O-ring at both connections.
Lubricate the O-rings with PAG 20 A/C oil before
attaching the lines.
2. Install the new receiver/drier, 1, onto the line 3
coming from the condenser. 4
3. Secure the receiver/drier with the brace and
hardware, 2, from removal.
4. Install the high pressure hose, 3, at the 1
receiver/drier. 2
5. Secure the coupler, 4, at receiver/drier. 86064003
6. Perform a vacuum test and after all checks are 73

Test” and “Charging” in this section.
EVAPORATOR/HEATER CORE
REPLACEMENT

Removal
1 2
1. Remove the five M6 bolts, 1. Each bolt will have
a flat washer and a rubber washer.
2. Remove the cab roof access panel, 2. When
removing the cover make sure not to tear the
seal, 3. 3
86064006
74
50-50
3. Drain the engine coolant and remove the heater
hoses, 1.
4. Disconnect the electrical harness to the blower 1
resistor, 2 and the temperature sensor, 3.
2
86064008
75
5. Remove the insulation tape (not shown) that is

wrapped around the lines going into the thermal 1 3
expansion valve.
6. Remove the internal hex head bolt, 1, that 2
secures the plate, 2, holding the high pressure
hose, 3, and low pressure hose, 4, into the
expansion valve.
4
86064009
76
7. Remove the tubing, 1, attached the bottom side

of the cab roof by removing the tie straps. 2
8. Remove the hardware, 2, that secures the HVAC
box to the cab roof. Each stud is secured with one
(1) M6 nut, one (1) spring lock washer and one 1
(1) flat washer.
9. Remove the HVAC box from the cab roof. 2
1
86064007
77
50-51
Disassembly
1 3
1. Remove the top cover, 1, by removing the seven
(7) screws, 2.
2. Remove the four screws, 3, that secure the
heater/evaporator in the HVAC box.
2
3
86064010
78
3. To separate the two cores, remove the screws, 1,

on each end of the core brackets.
86064011
79
Assembly
1. Attach the two cores and install the screws, 1, on
each end of the core brackets.
86064011
80
50-52
2. Install the heater/evaporator cores in the HVAC
box and secure with four screws, 1. Torque 2 1
hardware to 2.2 ± 0.2 N⋅m (20 ± 2 in-lb).
3. Install the top cover, 2 and secure with seven (7)
screws, 3.
IMPORTANT: Apply silicone sealant to all sheet

metal joints and seams.
IMPORTANT: Make sure insulation tubing is over the 3

freeze probe.
1
IMPORTANT: Install insulation tape to the coils of the 86064010
evaporator. 81
Installation
1. Install the HVAC box into the cab roof. 1 2
2. Install the hardware, 1, that secures the HVAC
(1) flat washer.
1
3. Install the drain tubes, 2 and secure with tie
straps, 3.
3
2
86064007
82

Lubricate the O-rings with PAG 20 A/C oil before 1 3
attaching the high and low pressure hoses.
5. Install the internal hex head bolt, 1, that secures 2
the plate, 2, holding the high pressure hose, 3,
and low pressure hose, 4, into the expansion
valve. Torque the bolt to 4.5 N⋅m (40 in-lbs).
6. Install the insulation tape (not shown) around the
lines going into the thermal expansion valve.
4
86064009
83
50-53
7. Install and secure the heater hoses, 1.
8. Connect the electrical harness to the blower
resistor, 2 and the temperature sensor, 3. 1
2
86064008
84
9. Install the cab roof access panel, 1. When

installing the cover make sure the seal, 2, is 3 1
intact.
10. Install the five M6 bolts, 3. Each bolt will have a
flat washer and a rubber washer. Torque the
hardware to 3.4 N⋅m (30 in-lbs).
2
86064006
85
EXPANSION VALVE

Removal
1 2
seal, 3. 3
86064006
86
50-54
3. Remove the insulation tape (not shown).
1
4. Remove the internal hex head bolt, 1 and remove
the clamping plate, 2.
5. Remove the high and low pressure hoses. 2
86064009
87
6. Remove the two M5 x 45 mm internal hex bolts,

1.
7. Remove the expansion valve, 2, and the two
O-rings, 3.
3
1
2
86064013
88
Installation
1. Install a new O-ring, 1, at both connections.
Lubricate the O-rings with PAG 20 A/C oil before
attaching expansion valve, 2.
2. Install the two M5 x 45 mm internal hex bolts, 3.
3
1
2
86064013
89
50-55
Lubricate the O-rings with PAG 20 A/C oil before 2
install the low and high pressure hoses.
4. Install the clamping plate, 1, and secure with the 1
internal hex head bolt, 2. Torque the bolt to 4.5
N⋅m (40 in-lbs).
5. Install the insulation tape (not shown).
86064009
90

intact.
2
86064006
91
TEMPERATURE SENSOR
1 2
Removal
3
seal, 3.
86064006
92
50-56
3. Remove the screws, 1, that secure the HVAC
cover.
86064008
93
4. Remove the temperature sensor probe, 1, from

the evaporator core. 2
5. Remove the screws, 2, that secure the switch to
the HVAC box. 1
6. Disconnect the harness at the switch, 3.
7. Remove the switch assembly.
86063998
94
Installation
2
1. Install the switch, 1, into the HVAC box.
2. Secure the switch to the box with screws, 2. 3
Torque hardware to 2.2 ± 0.2 N⋅m (20 ± 2 in lbs).
3. Connect the harness at the switch.
4. Install the temperature sensor probe, 3, in the
evaporator core at a distance of 90 mm (3.54 in).
IMPORTANT: Make sure the probe is covered with 1
insulation tubing.
86063998
95
50-57
5. Install the cover and secure with screws, 1.
86064008
96

intact.
2
86064006
97
BLOWER MOTOR/BLOWER MOTOR

RESISTOR

Removal
1 2
seal, 3. 3
86064006
98
50-58
hoses, 1.
4. Disconnect the electrical harness to the blower 1
resistor, 2 and the temperature sensor, 3.
2
86064008
99
5. Remove the insulation tape (not shown) that is
wrapped around the lines going into the thermal 1
expansion valve.
6. Remove the internal hex head bolt, 1, that 3
2
secures the plate, 2, holding the high pressure
hose, 3, and low pressure hose, 4, into the
expansion valve.
4
86064009
100
7. Remove the tubing, 1, attached the bottom side

of the cab roof by removing the tie straps. 2
8. Remove the hardware, 2, that secures the HVAC
(1) flat washer.
9. Remove the HVAC box from the cab roof. 2
1
86064007
101
50-59
Disassembly
2
1. Remove the screws that secure the blower motor
assembly, 1, to the HVAC box. 1 3
2. If only replacing the blower motor resistor, 2,
remove the screws, 3, that secure it to the motor.
86064014
102
Assembly
2
1. Install the screws that secure the blower motor
assembly, 1, to the HVAC box. 1 3
2. Install the blower motor resistor, 2. Install the
screws, 3, that secure the resistor to the motor.
86064014
103
Installation
1 2
1. Install the HVAC box into the cab roof.
2. Install the hardware, 1, that secures the HVAC
(1) flat washer.
1
3. Install the drain tubes, 2 and secure with tie
straps, 3. 3
2
86064007
104
50-60
Lubricate the O-rings with PAG 20 A/C oil before 1
attaching the high and low pressure hoses.
5. Install the internal hex head bolt, 1, that secures 3
2
the plate, 2, holding the high pressure hose, 3,
and low pressure hose, 4, into the expansion
valve. Torque the bolt to 4.5 N⋅m (40 in-lbs).
6. Install the insulation tape (not shown) around the
lines going into the thermal expansion valve.
4
86064009
105
7. Install and secure the heater hoses, 1.

8. Connect the electrical harness to the blower
resistor, 2 and the temperature sensor, 3. 1
2
86064008
106

intact.
2
86064006
107
50-61
LOW PRESSURE SWITCH

IMPORTANT: The low pressure switch can be
replaced without discharging the system.
Replacement
1. Remove the connector, 1, from low pressure
switch.
2
2. Remove the low pressure switch, 2.
3. Install new switch. Attach the connector to 1
switch.
86064001
108
HIGH PRESSURE SWITCH
IMPORTANT: The high pressure switch can be
1
replaced without discharging the system.
Replacement
1. Remove the connector, 1, from high pressure
switch.
2
2. Remove the high pressure switch, 2.
3. Install new switch. Attach the connector to
switch.
86064001
109
50-62
A/C COMPRESSOR
IMPORTANT: If servicing the A/C compressor is
required, contact your authorized Sanden dealer for
more information.


Removal
1. Loosen pulley bolt, 1, to allow pulley movement.
2. Loosen jam nut, 2 and turn bolt, 3, counterclock-
wise to loosen the belt.
3. Remove the belt, 4, from the pulleys.
2 1
3
4
86064002
110
4. Remove the high pressure line, 1 and low
pressure line, 2 from the compressor.
1
86064001
111
50-63
5. Remove the air filter cover, 1. Remove the air
filter from housing.
6. Disconnect the clutch harness, 2.
1
86063996
112
7. Remove the lower A/C compressor mounting
bolt and nut, 1.
8. Remove the rear A/C compressor mounting bolt,
2.
9. Remove the compressor from the tractor.
2
1
86064015
113
50-64
COMPRESSOR ASSEMBLY TORQUES
Item N⋅m ft-lb

Armature retaining nut, 1/2″ -- 20 30.4 ± 3.9 22.4 ± 2.9
Armature retaining nut, M8 17.7 ± 2.9 13.0 ± 2.2
Cylinder head bolts, M6 13.7 ± 2.9 10 ± 2.2
Cylinder head bolts, M8 34.3 ± 4.9 25.3 ± 3.6
Oil filler plug 19.6 ± 4.9 14.5 ± 13.6
Hose fitting 1″ -- 14 rotolock 36.3 ± 3.9 26.7 ± 2.9
7/8″ Tube-O 32.4 ± 3.9 23.9 ± 2.9
3/4″ Tube-O 23.5 ± 3.4 17.3 ± 2.5
Pad fitting bolt, M10 39.2 ± 3.9 28.9 ± 2.9
Pad fitting bolt 3/8″ -- 24 39.2 ± 3.9 28.9 ± 2.9
Pad fitting bolt, M8 34.3 ± 3.9 26.3 ± 2.9
Clutch lead wire clamp screw 1.3 ± 0.3 11 ± 3 in-lb
High pressure relief valve 9.8 ± 2.0 7.2 ± 1.4
Thermal protector switch clamp bolt 9.8 ± 2.9 -- 2.0 7.2 ± 2.2 -- 1.4
Clutch dust cover screws (6 -- M5) 9±2 6.5 ± 1.4
Clutch dust cover screws (3 -- 1/4″ -- 20) 3.6 ± 1.2 2.7 ± 0.9
50-65
COMPRESSOR BREAKDOWN
5 9
6 7 8
10
1 3
2 4
86064016
114
1. Shaft Key*
2. Felt Ring*
3. Shaft Seal Snap Ring*
4. Lip Seal with O-ring*
5. Oil Plug
6. Block Gasket*
7. Valve Plate Assembly*
8. Head Gasket*
9. Cylinder Head*
10. Cylinder Head Bolt
11. Shaft Seal Kit -- 2, 3, and 4
12. Valve Plate Kit -- 6, 7, and 8
13. Cylinder Head Kit -- 8 and 9
14. Gasket Kit -- 6 and 8
*Serviced only as a kit.
50-66
CLUTCH BREAKDOWN
1. Shaft Nut*
2. Armature Plate* 5
3. Clutch Shims*
1 6
4. Rotor Snap Ring* 3 7 8
5. Rotor Bearing Dust Cover (SD-5)
6. Rotor Assembly*
7. Field Coil Assembly Snap Ring*
8. Field Coil Assembly
9. Accessory Kit (1, from previous figure) -- 1, 4, 5 and
7
10. Armature / Rotor Assembly Kit -- 2 and 6
2 4
*Serviced only as a kit.
86064017
115
Compressor Repaired Internally and Reinstalled
in the System
1. Before making repairs, drain the oil from the
compressor.
• Remove the oil plug and drain as much oil as
possible into a suitable container.
• Drain oil from the suction and discharge ports
into a suitable container while turning the
armature shaft clockwise.
86064018
116
2. Measure and record the amount of oil drained
from the compressor.
3. Inspect the oil for signs of contamination such as
discoloration or foreign material.
4. Repair the compressor as needed.
86064019
117
50-67
5. Add the same amount of new oil to the
compressor as was measured. Be sure to use
the correct oil for the compressor.
6. Reinstall oil plug. Seal and O-ring must be clean
and not damaged. Torque to 15 -- 20 N⋅m (11 -- 15
ft-lb). Be careful not to cross thread the oil plug.
86064020
118
Sanden Compressor Replaced by a New Sanden
Compressor of the Same Type
1. Drain oil from the old compressor; measure and
record the amount.
2. Drain oil from the new compressor.
3. Add new oil of the correct type to the new
compressor. Use the same quantity as was
removed from the old compressor.
4. Reinstall oil plug. Seal and O-ring must be clean
and not damage. Torque to 15 -- 20 N⋅m (11 -- 25
ft-lb).
50-68
CLUTCH HEAD REPAIR

Keyed Shaft Armature Removal
NOTE: Keyed shaft can be identified in that the holes
for the armature plate spanner will have threads in
them.
1. Insert pins of armature plate spanner into

threaded holes of armature assembly.
2. Hold armature assembly stationary while
removing retaining nut.
86064021
119
3. Remove armature assembly using puller. Thread
3 puller bolts into the threaded holes in the
armature assembly. Turn center screw clockwise
until armature comes loose.
86064022
120
4. If shims are above shaft key, remove them now.
If shims are below shaft key, and key and bearing
dust cover (if applicable) must be removed
before shims can be removed.
5. Remove bearing dust cover (if applicable).
NOTE: When removing cover, make sure not to
distort.
6. Remove shaft key by tapping with a flat blade

screwdriver and hammer.
7. Remove shims with a pointed tool and a small
screwdriver. 86064023
121
50-69
Rotor Assembly Removal
1. If bearing dust cover has not been removed,
remove it now. See Keyed Shaft Armature
Removal.
2. Remove internal snap ring.
3. Remove rotor snap ring.
4. Remove shaft key.
5. Remove rotor pulley assembly:
• Insert the lip of the jaws into the snap ring
groove.
86064024
• Place rotor pulley shaft protector (Puller set)
over the exposed shaft. 122
• Align thumb screws to puller jaws and finger
tighten. Turn puller center bolt clockwise
using a socket wrench until rotor pulley is
free.
Field Coil Assembly Removal
1. Loosen lead wire clamp screw with screwdriver
until wire(s) can be slipped out from under clamp.
2. Undo any wire connections on the compressor
which would prevent removal of the field coil
assembly.
3. Remove snap ring.
4. Remove the field coil assembly.
86064025
123
Field Coil Assembly Installation
IMPORTANT: Protrusion on underside of coil ring
must match hole in front housing to prevent
movement and correctly locate lead wire(s).
1. Install field coil assembly.

2. Install snap ring.
3. Install and secure lead clamp screw.
86064025
124
50-70
Rotor Assembly Installation
1. Place compressor on support stand, supported
at rear end of compressor.
IMPORTANT: If the compressor must be clamped in
a vise, clamp only on the mounting ears, never on the
body of the compressor.
2. Set rotor squarely over the front housing boss.

3. Place the rotor installer ring into the bearing bore.
Ensure that the edge rests only on the inner race
of the bearing, not on the seal, pulley, or outer
race of the bearing. 86064026
4. Place the driver into the ring and drive the rotor 125
down onto the front housing with a hammer or
arbor press. Drive the rotor against the front
housing step.
5. Install rotor bearing snap ring, if it has been
removed.
6. Install rotor retaining snap ring.
IMPORTANT: If a bevel is present on the snap ring,
it should face up (away from the body of the
compressor).
7. Install rotor bearing dust cover.
86064023
126
Armature Assembly Installation
1. Install shaft key with pliers.
2. Install clutch shims.
IMPORTANT: Clutch air gap is determined by shim
thickness. When installing a clutch on a compressor,
try the original shims first. When installing a clutch on
a compressor that has not had a clutch installed
before, first try 1.0, 0.5, 0.1 mm (0.04, 0.02 and 0.004
in) shims.
86064027
127
50-71
3. Align keyway in armature assembly to shaft key.
Using driver and a hammer, drive the armature
assembly down over the shaft until it bottoms on
the shims. A distinct sound change will be noted
if driving with a hammer.
4. Install retaining nut and torque to specification.
1/2″-20: 27 -- 34 N⋅m (20 -- 25 ft-lb)
M8: 15 -- 21 N⋅m (11 -- 15 ft-lb)
86064028
128
5. Check air gap with feeler gauge. Specification is
0.4 -- 0.8 mm (0.016 -- 0.031 in). If gap is not even
around the clutch, gently tap down at the high
spots. If the overall gap is out of spec., remove
the armature assembly and change the shims as
necessary.
86064029
129
Replacement of Shaft Seal
NOTE: Lip seal assembly and felt ring must never be
reused. Always replace these components.
1. Be sure all gas pressure inside the compressor

has been relieved.
2. Remove armature assembly, rotor bearing dust
cover(if applicable), shaft key, and clutch shims.
3. Remove the retainer and felt ring.
86064030
130
50-72
4. Remove seal snap ring.
86064031
131
5. Remove lip seal assembly with removal and
installation tool. Twist the tool until the 2 lips on
the tool engage the slots in the lip seal housing
and pull the seal out with a twisting motion.
6. Clean out shaft seal cavity thoroughly. Debris
can be removed using a non-petroleum based
solvent and lint free cloth. The area should then
be blown out with clean, dry compressed air.
Make sure all foreign material is completely
removed.
86064032
132
7. Install shaft seal protective sleeve over compres-
sor shaft. Inspect the sleeve to ensure that it has
no scratches and is smooth so that the lip seal will
not be damaged. Make sure there is no gap
between the end of the sleeve and the seal
surface on the shaft.
8. Engage the lips of the seal removal and
installation tool with the slots in the new lip seal
housing. Make sure the lip seal assembly,
especially the O-ring, is clean. Dip the entire lip
seal assembly, on the tool, into clean refrigerant
oil. Make sure the seal assembly is completely
covered with oil. 86064033
9. Install lip seal over shaft and press firmly to seat. 133
Twist the tool in the opposite direction to
disengage it from the seal and withdraw the tool.
50-73
10. Install shaft seal snap ring.
NOTE: Beveled side should face up (outward/away
from compressor body). Ensure that snap ring is
completely seated in groove. It may be necessary to
tap the snap ring lightly to seat it in the groove.
86064031
134
11. Tap new felt ring assembly into place.
12. Reinstall clutch shims, shaft key, rotor bearing
dust cover (if applicable), and armature
assembly.
13. Check and adjust air gap as necessary.
86064034
135
50-74
Cylinder Head Removal
1. Be sure all internal compressor pressure has
been relieved.
2. Inspect cylinder head for fitting or thread
damage. Replace if damaged.
3. Remove cylinder head bolts.
4. Use a small hammer and gasket scraper to
separate the cylinder head from the valve plate.
Be careful not to scratch the gasket surface of the
cylinder head.
5. Carefully lift the cylinder head from the valve 86064035
plate. 136
IMPORTANT: It is recommended that both the head
gasket (between the cylinder head and the valve
plate) and the block gasket (between the valve plate
and the cylinder block) be replaced any time the
cylinder head is removed. However, if no service is
required to the valve plate, it may be left in place. If
the valve plate comes loose from the cylinder block,
the block gasket must be replaced.
6. Carefully remove old head gasket from top of

valve plate with gasket scraper. Be careful not to
disturb valve plate to cylinder block joint if valve
plate has been left in place. If valve plate comes 86064036
loose from cylinder block, proceed to Valve Plate
Removal, and replace block gasket. 137
50-75
Valve Plate Removal
1. Using a small hammer and gasket scraper,
carefully separate valve plate from cylinder
block. Be careful not to damage sealing surface
of cylinder block.
2. Inspect reed valves and retainer. Replace valve
plate assembly if any part is damaged.
3. Carefully remove any gasket material remaining
on valve plate, cylinder block or cylinder head.
Do not damage sealing surfaces on compo-
nents.
Valve Plate and Cylinder Head Installation
1. Large gasket: OD of block gasket is 120 mm
(4-3/4 in) and sealing face of block does not have
a 114.7 mm (4-1/2 in) diameter step.
2. Small gasket: OD of gasket is 114.7 mm (4-1/2 in)
and sealing face of the cylinder block has a 114.7
mm (4-1/2 in) diameter step.
3. Coat new block gasket with clean refrigerant oil.
4. Install block gasket. Align new gasket to location
pin holes and orifice(s). Notch (if applicable)
should face same direction as oil plug or adapter.
5. Place valve plate on cylinder block with
discharge valve, retainer and nut facing up (away
from cylinder block) and location pins properly 86064037
located in holes. 138
6. Use vacuum pump and small tube to remove
residual oil from each bolt hole.
IMPORTANT: If this step is not performed, hydraulic
pressure can be created when the cylinder head
bolts are tightened. This pressure can break the
cylinder block.
7. Coat head gasket with clean refrigerant oil.

8. Install head gasket cover location pins. Checking
for correct orientation.
9. Install cylinder head.
10. Install cylinder head bolts and tighten in a star
pattern.
Step 1: Torque to approximately 19.6 N⋅m (14
ft-lb).
Step 2: Torque to 32.4 -- 36.3 N⋅m (24 -- 27 ft-lb).
86064038
139
50-76
SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1
Chapter 1 -- Electrical
CONTENTS

Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Heat/Accessory/Run Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Start Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Light Switch Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Light Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
“Off” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
“Taillight/Instrument Panel” Position (middle position) . . . . . . . . . . . . . . . . . . . . . . . 18
“Headlight Position” (forward position) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Light Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
55 404 Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
55-1

55 404 Taillight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
“Off” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
“On” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
55 408 Transmission Range Safety Switch (HST and Gear) . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
55 408 Mid PTO Safety Switch (Optional for DX35, DX45 and DX40 Models Only) . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
(DX) Series Relay Panel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
(D) Series Relay Panel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
“HI”, “LOW”, Cruise Control, Fuel Shutoff, PTO Safety, and Glow Plug Lamp Relays . . 35
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
55-2

Headlight and Neutral Start Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Module Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Glow Plug Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Hi/Low Transmission Range Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Optional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
55-3

Hi/Low Transmission Range Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Extended Position (Not Shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
55-4

4T, 4 3.6-5.8 4.9-7.9
M6 7T, 7 1.0 5.9-9.4 7.9-12.7 ------ ------ ------
8T, 8, 11 7.2-10 9.8-13.6
4T 7.2-14 9.8-19 12-17 16.3-23
M8 7T 1.25 17-22 23-29.8 1.0 19-27 25.7-36.6
8T 20-26 27.1-35.2 22-31 29.8-42
4T 20-25 27.1-33.9 20-29 27.1-39.3
M10 7T 1.5 34-40 46.1-54.2 1.25 35-47 47.4-63.7
8T 38-46 51.5-62.3 40-52 54.2-70.5
4T 28-34 37.9-46.1 31-41 42-55.6
M12 7T 1.75 51-59 69.1-79.9 1.25 56-68 75.9-92.1
8t 57-66 77.2-89.4 62-75 84-101.6
4T 49-56 66.475.9 52-64 70.5-86.7
M14 7T 2.0 81-93 109.8-126 1.5 90-106 122-143.6
8T 96-109 130.1-147.7 107-124 145-168
4T 67-77 90.8-104.3 69-83 93.5-112.5
M16 7T 2.0 116-130 157.2-176.2 1.5 120-138 162.6-187
8T 129-145 174.8-196.5 140-158 189.7-214.1
4T 88-100 119.2-136 100-117 136-158.5
M18 7T 2.0 150-168 203.3-227.6 1.5 177-199 239.8-269.6
8T 175-194 237.1-262.9 202-231 273.7-313
4T 108-130 146.3-176.2 132-150 178.9-203.3
M20 7T 2.5 186-205 252-277.8 1.5 206-242 279.1-327.9
8T 213-249 288.6-337.4 246-289 333.3-391.6
55-5
Op. 55 100
The D(DX) Series Class 3 electrical system is a
12-volt negative (--) ground system consisting of 3
main wiring harnesses.
COMPONENT LOCATION AND FUNCTION

2 4 3 6D
8
7
1
6B
6C
30002187
6A
1
24 21 5 18
23 9
25
16
22
30002188 19 17
2
14 15 10 11
B
A
30002189
13 12 19 20 C
55-6
1. Battery -- Located under the hood, in front of the 12. Starter – Located on the left side of the engine;
radiator; electrical power source. BCI Group 47. rotates the engine for starting.
2. Main Fuse (40 Amp.) -- Located on the left side 13. Alternator (40 Amp.) – Located on the left side
of the engine directly above the starter; protects of the engine; generates power to charge the
the entire electrical system from damage due to battery.
excessive current.
14. Engine Oil Pressure Switch – Located in front
3. Fuse Block – Located underneath instrument of the cylinder head; provides warning of low
panel; contains fuses that protect individual engine oil pressure.
circuits from damage due to excessive current.
15. Engine Coolant Temperature Sending Unit –
4. Relay/Diode Panel – Located behind the left Located in the thermostat housing on the front
side panel; houses relays utilized by individual left side of the engine; warns the operator of high
circuits and diodes which direct current within a operating temperatures.
circuit to allow the use of one wire within multiple
16. Fuel Level Sending Unit – Located inside the
circuits to control a relay.
fuel tank; sends a signal indicating fuel level to
5. Key Switch – Located on the right side of the the instrument panel.
operator’s console; used to switch battery power
17. Fuel Shutoff Solenoid – Located on the right
on or off to the tractor’s electronic circuits, supply
side of the engine; shuts off the fuel flow to the
power to the engine glow plugs, or to start the
injection pump to stop the engine.
tractor.
18. Engine Glow Plugs – Located on the right side
6. Safety Start Switches (4) – Shuttle for 12 x 12
of the cylinder head, adjacent to the fuel
transmission and range gear (A)HST transmis-
injectors; aid in engine startup by warming the air
sion, rear PTO (B), mid PTO (if equipped) (C),
in the combustion chamber.
and the operator’s seat switch (D); will not allow
the tractor to start with the transmission or the 19. Parking Brake Switch – Located under the right
PTO engaged, or without an operator in the (A) (standard), left (B)(deluxe), platform; actu-
operator’s seat. ates with the parking brake mechanism;
indicates when the parking brake is engaged by
NOTE: The parking brake switch also lights the
illuminating a light on the instrument panel.
parking brake indicator light on the instrument panel
when the parking brake is engaged. 20. Brake HST Cruise Release Switch – (Deluxe
Only) – Located under the left near the brake
NOTE: The tractor may be started without the pedal pivot shaft; releases the HST speed control
operator being seated when the parking brake lever when the brakes are applied.
is engaged. 21. HST Cruise Control Switch (Deluxe Only) –
Located on the right fender; controls current to
7. Headlights – Located on the front grill of the the speed control magnet.
tractor; Economy models have two headlights,
Deluxe models have four headlights; headlights 22. HST Control Magnet (Deluxe Only) – Located
illuminate the area in front of the tractor. on the right transmission side of the steering
column; locks the HST linkage in place to set
8. Taillights/Directional Signals/Flasher Warning constant transmission speed.
(Hazard) Lights – Located at the rear of the
tractor, on both sides of the ROPS; provide 23. Rear Work Light (50 Watt Halogen) (Optional)
warning during transportation and emergency. – Located on the right side of the ROPS; power
leads for the light are provided on the right fender
9. Instrument Panel – Located in the center of the wiring harness.
dash panel; houses gauges and indicator lights
that monitor tractor functions. 24. HST Hi/Lo Range Selector Switch (Deluxe
Only) – Located on the right fender; momentary
10. Light Switch – Located on the left side of the toggle switch used to select either of the two
dash panel; switches the headlight, taillight and different HST gear ranges. Located on optional
the instrument panel lights on or off. front two spool valve control handle.
11. Hazard (Flashing Warning Lights) Switch – 25. Auxiliary Electrical Power Socket – Located at
Located on the left side of the dash panel; the right rear of the operator’s platform; provides
switches the flashing warning (hazard) lights on electrical current for any auxiliary 12 volt
and off. electrical item (15 amp maximum).
55-7
Op. 55 100
WIRING HARNESSES (Figure 3) Grounds

A. Hood 1. Negative battery post to the right side of the frame.
B. Front Main (includes engine and relay areas) 2. Starter Mounting Bolt
C. Rear Chassis 3. Left Side behind rear tire on HPL Housing
50043929
30997565
50043931
55-8
ELECTRICAL SYSTEM COMPONENTS

WARNING
Before working on any component of the
electrical system, the negative (--) battery cable
should be disconnected from the battery, as
electrical shock or damage to the system
components may occur. Some testing requires
12-volt power; use caution whenever power is
used.
BATTERY
The tractor is equipped with a BCI group 47, 12-volt
battery with a minimum cold cranking ability of 600
amps at 0°F (-18°C).
Make sure the battery connections are tight and free

of corrosion. A solution of baking soda and water may
be used to wash the outside surface and terminals of
the battery when necessary. However, make sure the
solution does not get inside the battery. After
cleaning, wash the battery with clean water, then
apply a small amount of petroleum jelly to the
terminals to prevent corrosion. 30997558
In freezing temperatures, a good battery charge 7

must be maintained. If the battery becomes
discharged or run down, the electrolyte becomes
weak and may freeze, causing damage to the case.
If you must add water, use distilled water. Add the
water just before using the tractor so that the water
will mix with the electrolyte during the charging
process, thus preventing the water from freezing.
To determine the battery charge, check the specific

gravity of the electrolyte.
55-9
Checking the Electrolyte Level
NOTE: Check the battery electrolyte level after every
50 hours of operation.
WARNING
Always check the electrolyte level with the tractor
engine off, as an explosive gas is produced inside
the battery when the alternator is charging. Do not
use an exposed flame and do not smoke when
checking the battery electrolyte level.
To check the battery electrolyte level:

1. Clean the top of the battery, then remove the vent
plugs.
2. Add distilled water if the electrolyte level is low.
The level is correct when the liquid is 1/4″ (6.35
mm) above the plates.
NOTE: Keep distilled water in a non-metallic
container that is clean and well-covered.
3. Install the vent plug after making sure the vent
holes are not blocked. At below freezing
temperatures, run the engine for a period of time
after adding water, allowing the battery to charge,
which prevents the water from freezing.
Removal
1
1. Release and lift the tractor engine cover.
2. Disconnect the negative (--) battery cable.
3. Disconnect the positive (+) battery cable.
4. Remove the hardware, 1, securing the battery.
5. Carefully remove the battery from the tractor.
IMPORTANT: Crossing the battery terminals may
cause damage to the electrical system.
Installation
30002190
NOTE: When replacing the battery, use only a BCI
group 47, 12volt battery. Make sure the battery fits 8
the battery tray correctly and is properly secured with
the mounting hardware. Never use a battery that
does not fit properly in the battery tray. Do not
overtighten the battery securing hardware. Do not
overtighten the battery cables.
1. Place the battery in the battery tray with the
battery posts towards the front of the tractor.
2. Use the battery hold down hardware, 1, to secure
the battery in the battery tray.
3. Connect the positive (+) cable to the positive
terminal.
4. Connect the negative (--) cable to the negative
terminal.
5. Lower and secure the tractor engine cover.
55-10
MAIN FUSE
The main fuse is a 40-amp maxifuse, 1, located on 1
the left-hand side of the engine and positioned above
the starter. This fuse protects the tractor’s entire
electrical system.
30997565
9
Replacement
2
To replace the main fuse:
1. Unplug the connector to expose the fuse.

2. Remove the old fuse, 2, from the fuse holder and
replace.
IMPORTANT: Always replace this fuse with a similar
40 amp fuse; DO NOT increase amperage rating.
19998319
10
55-11
FUSE BLOCK
NOTE: The fuse block is configured the same for
both models except for the 5 th fuse position. The
economy model (shown) uses a 5-amp fuse, which
is used for alternator excitation. The deluxe model
uses a 7.5 amp fuse, which is used for alternator
excitation, the cruise relay, and transmission shift
control.
To gain access to the fuse panel, remove the two
instrument panel mounting screws, 1, lift the 1
instrument panel from the body panel. The fuse block
is located on the left side of the instrument panel
opening. Always replace blown fuses with the size
specified for that circuit.
50045711
11
From left to right as viewed from above the tractor,
the fuse block contains the following fuses:
Fuse Fuse Circuit Protected

Cavity Size
1 7.5 amp Voltage regulator, Glow plug
auto heat control
2 8 amp Operator safety system,
Circuit fuel solenoid 1 2 3 4 5 6 7
breaker
3 10 amp Turn signals, flasher cutoff and
auxiliary work light relays
4 7.5 amp Instrument panel lights, taillights, 50031486
Front lamps relay
12
5 7.5 amp Battery charging light,
Cruise control and Range shift
relays (HST -- equipped ONLY)
6 15 amp Hazard flasher lights,
Auxiliary rear work light
7 20 amp Front headlamps, Auxiliary
power socket (HST -- ONLY)
55-12
KEY SWITCH
The key switch is located on the right side of the
operator’s console. The key switch has three
key-operated positions, which are: STOP, 1, 1
HEAT/ACCESSORY/RUN, 2, and START, 3. Turning
the key clockwise from the stop position will align the 2
electrical contacts within the key switch. With the 3
contacts aligned, the circuit is closed and the battery
current will flow through the circuit.
In the STOP position, 1, there is no battery power

supplied to electrical circuits and the key may be
removed from the switch to prevent unauthorized
use of the tractor. The STOP position, 1, also stops 10998333
the tractor engine, when running. When the key is in
the HEAT/ACC/RUN position, 2, battery current 13
flows to the engine glow plugs to aid in starting the
engine when the engine is cold. The HEAT/ACC/
RUN position, 2, also allows current to flow from the
battery to the tractor accessories without the engine
running. The switch will also be in this position while
the tractor is running. When the key is in the START
position, 3, power is supplied to the starter motor to
crank and start the engine. The key switch is spring
loaded and will return from the START position,3, to
the HEAT/ACC/RUN position, 2.
The key switch is not serviceable and must be

replaced if troubleshooting determines the switch is
defective.
Removal
1. Raise the tractor engine cover.
2. Disconnect the negative (--) battery cable from
the negative (--) battery terminal.
3. Remove the two retaining bolts, 1, from the inside
of the tractor firewall, to loosen the right side
cover, 2.
30002141
14
55-13
4. Remove the two retaining bolts, 1, from the left
side cover of the tractor.
5. Carefully turn the right cover to reveal the key
switch.
6. Disconnect the key switch from the wiring
harness.
7. Remove the plastic retaining nut on the key
switch to remove the switch from the right cover. 1
30002142
15
Terminal Identification
A Start
B 12 V Input
C ACC Terminal
D 12 V Input
Testing
Use an ohmmeter to test each position of the key
switch for electrical continuity.
Stop Position (Not Shown) 30002125

1. With the key switch in the stop position, continuity 16
should not exist between any of the terminals. If
continuity exists between any of the terminals
while the switch is in the “stop” position, the key
switch is defective and needs replaced.
Heat/ Accessory/ Run Position
When the key switch in the “Heat/ ACC/Run”
position, continuity should exist between the “B” and
“C” terminals.
1. Make sure the switch is in the “Heat/ACC/Run”

position.
2. Using an ohmmeter, touch one of the test probes
to terminal “B”. Touch the other test probe to
terminal “C”.
3. Observe the ohmmeter. The ohmmeter should
show little or no resistance indicating that 30002126
continuity exists between terminal “B” and
terminal “C”. If continuity does not exist between 17
terminal B” and terminal “C”, the key switch is
defective and needs replaced.
NOTE: Continuity should not exist between
terminals A and D in the “Heat/ACC/Run” position.
55-14
Start Position
Make sure the key switch is in the “Start” position.

terminal “C”.
show little or no resistance indicating that
terminal “C”. If continuity does not exist between
terminal “B” and terminal “C”, the key switch is
30002126
18
3. Following the procedure outlined in the previous
2 steps, test terminals “A” and “D”. With the Key
in the “Start” position, continuity should exist
between the “A” and “D” terminals.
30002127
19
LIGHT SWITCH
The light switch is located on the left side of the
instrument panel, outboard of the flasher warning
light rocker switch. This is a rocker-type switch
having three positions:
• Depressed fully rearward (as shown) = OFF

• Centered (One position forward) = Instrument 1
panel lights and taillights ON
• Depressed fully forward = Panel lights, taillights
and headlights ON
50043966
The key switch must be in the “ACC/RUN” position
for these lights to operate. 20
55-15
Light Switch Removal
the left side of the firewall of the tractor.
30003983
21
4. Disconnect the wiring harness from the light
switch.
30002142
22
5. Remove the light switch, 1, from the dash panel
by releasing the locking tabs on the switch and
pushing the switch upwards through the dash
panel.
50043966
23
55-16
Light Switch Testing
Use an ohmmeter to test each position of the light
“Off” Position
1. In the “off” position, continuity should exist
between terminals 7 and 3 only.
to terminal 7. Touch the other test probe to
terminal 3.
continuity exists between terminal 7 and terminal
3. If continuity does not exist between terminal 7
and terminal 3, the light switch indicator bulb is
defective and the switch needs replaced. 30002206
24
55-17
“Taillight/ Instrument Panel” Position (middle
position)
1. Using an ohmmeter in the same manner as
described in the previous two steps, touch one of
the test probes to terminal 2. Touch the other test
probe to terminal 3.
and terminal 3, the light switch is defective and
needs replaced.
30002205
to terminal 7. Touch the other test probe to 25
terminal 2.
30002204
26
terminal 3.
30002206
27
55-18
“Headlight Position” (forward position)
1. Push the light switch in the forward position.
terminal 3.
needs replaced.
30002205
28
terminal 6.
needs replaced.
30002207
29
terminal 2.
30002204
30
55-19
terminal 3.
30002206
31
Light Switch Installation
1. Connect the wiring harness, 1, to the light switch,
2. 2
2. Insert the light switch into the dash panel until the
locking tabs click into place.
3. Install the left side panel using the four retaining 1
bolts.
4. Connect the negative (--) battery cable to the
negative (--) battery terminal.
5. Lower the tractor engine cover.
30003984
32
55-20
Op. 55 404
HEADLIGHT
There are for halogen front head lights on the (D) and
(DX) series tractors.
10036706
33
Replacement
If any of the four headlamps fails to operate, the bulb
must be replaced. To change a bulb:
1. Open the tractor hood.

2. Rotate the bulb socket counterclockwise a
quarter turn and remove the socket from the
housing.
3. Pull the defective bulb straight out of the socket.
4. Install a new bulb in the socket by pushing it
straight in until it bottoms.
IMPORTANT: Be careful not to touch the new bulb
34
with bare fingers, as oils from the skin can shorten the
life of the bulb. Use a protective cloth or gloves when
installing halogen bulbs.
5. Re-install the socket into the housing and rotate

it clockwise a quarter-turn to lock it into place.
NOTE: Replace the defective bulb with a size 894
halogen bulb.
55-21
Op. 55 404
TAILLIGHT
The taillights, 1, are located on the left and right rear
ROPS uprights. The taillights illuminate the rear of
the tractor to provide warning to approaching
vehicles.
NOTE: The same procedure is used for both sides.
To replace a taillight bulb:
1. Remove the two screws, 2, retaining the taillight

4
3
lens and remove the lens.
1 2
10034983
35
2. Remove the defective bulb, 3, by turning it
counterclockwise and pulling it out of the socket.
3. Install the new bulb by pushing it into the socket
and rotating it clockwise until it locks into place.
NOTE: Replace the defective bulb with a new #1156
bulb.
10034986
36
NOTE: The same procedure is used on both sides.
To replace a flasher bulb:

5
1. Remove the two screws, 4, (Figure 35), retaining
the flasher/turn signal lens and remove the lens.
10034984
bulb.
37
55-22
HAZARD LIGHT SWITCH

The hazard light switch, 1, is a two-position,
rocker-type switch located on the left-hand side of
the tractor dash panel.
The two positions of the hazard light switch are:

• OFF POSITION (Safety symbol protruding out of
1
switch)
• ON POSITION (Safety symbol pushed into
switch)
An internal indicator bulb flashes when the hazard

light switch is in the “on” position.
50043966
The hazard lights will operate regardless of the key
38
switch position.
Removal
20003983
39
5. Disconnect the wiring harness from the light
switch.
6. Remove the light switch from the dash panel by
releasing the locking tabs on the switch and
pushing the switch through the dash panel.
30002142
40
55-23
Testing
Use an ohmmeter to test both of the positions of the
hazard light switch for electrical continuity.
“Off” Position
terminal 2.
and terminal 2, the switch is defective and needs
replaced.
30002193
41
terminal 7.
and terminal 7, the internal indicator bulb is
defective and the switch needs replaced.
30004012
42
“On” Position
terminal 3.
replaced.
20004013
43
55-24
terminal 6.
replaced.
20004014
44
terminal 7.
Installation
1. Insert the hazard light switch into the dash panel 20004012
until the locking tabs click into place.
45
2. Connect the wiring harness to the hazard light
switch.
3. Install the left side panel using the four retaining
bolts.
4. Connect the negative (--) batter cable to the
55-25
Op. 55 408
TRANSMISSION RANGE SAFETY SWITCH

(HST AND GEAR)
The transmission range safety switch, 1, is a
single-pole, push-button type switch located under-
neath the left side operator’s platform. When the
transmission is in high or low range, the contacts in 1
the switch are open, not allowing the tractor to start.
When the transmission is in the neutral range
position, the contacts in the switch are closed
completing the circuit. This allows the tractor to start.
NOTE: The transmission range safety switch may be

tested for continuity without removing the switch from
the tractor, but it is recommended that the switch be
removed for testing. Follow the same test procedure 30004047 HST
outline when the switch is removed from the tractor.
46
20004016 Gear
47
Removal
1. Raise the tractor engine cover. 1
3. Disconnect the transmission range safety switch
leads from the wiring harness.
4. Remove the transmission range safety switch, 1,
with the rubber washer, 2, from the transmission 2
case. 3
NOTE: The HST range shift rail, (Deluxe) and the 12 x
12 shuttle shift rail, (Economy), operate the transmission 30002200
range safety switch. Grooves in the shift rails accept the 48
balk pin, extending the plunger in the safety switch,
when the range or shuttle control levers are in neutral.
This completes the circuit, allowing the tractor to start.
5. Use a pencil magnet to remove the balk pin, 3, from

the transmission range safety switch hole in the
transmission case. Inspect the balk pin, 3, for
damage.
55-26
Testing
transmission range safety switch for electrical continuity.
Extended Position
EXTENDED
1. With the transmission range safety switch in the
“extended” position, touch one of the test probes
to the one switch lead. Touch the other test probe
to the other switch lead.
continuity exists between the two leads. If
continuity does not exist, the switch is defective
and needs replaced.
Retracted Position (Not Shown) 30002201

3. Using an ohmmeter, continuity should not exist 49
between the two leads. If continuity exists
between the two leads while the switch is in the
“retracted” position, the switch is defective and
needs replaced.
Installation
1. Insert the balk pin, 3, into the transmission range
safety switch hole in the transmission case.
2. Install the transmission range safety switch, 1,
with the rubber washer, 2, into the transmission
case.
3. Connect the wiring harness to the transmission
range safety switch leads.
55-27
Op. 55 408
1
REAR (MAIN) PTO SAFETY SWITCH
The rear PTO safety switch, 1, is a single-pole,
push-button type switch located underneath the left
side operator’s platform on the PTO linkage. When
the PTO is engaged, the contacts in the switch are
open, not allowing the tractor to start. When the PTO
is disengaged, the contacts in the switch are closed,
NOTE: Remove the left wheel assembly for easier
access to the rear PTO safety switch. Be sure to provide
adequate support to the rear axle during repairs. 30002199
NOTE: The PTO safety switch may be tested for 50

continuity without removing the switch from the
tractor, but it is recommended that the switch be
removed for testing. To test the switch in the tractor,
follow the same procedure used when the switch is
removed from the tractor.
3. Disconnect the rear PTO safety switch leads
from the wiring harness.
4. Remove the retaining nut, which secures the rear
PTO safety switch to the PTO linkage.
5. Remove the rear PTO switch by pressing in on
the locking tabs and sliding the switch upward out
of the support bracket.
Testing
rear PTO safety switch for electrical continuity.
Extended Position
With the rear PTO safety switch in the “extended” (out)
position, continuity should not exist between the two
switch leads. If continuity exists between the switch
leads while the switch is in the “extended” position, the
rear PTO safety switch is defective and needs replaced.
30003985
51
55-28
Retracted Position
With the rear PTO safety switch in the “retracted” (in)
position, continuity should exist between the two
switch leads. If continuity does not exist between the
switch leads while the switch is in the “retracted”
position, the switch is defective and needs replaced.
30002203
52
Op. 55 408
MID PTO SAFETY SWITCH (Optional for

35DA, 45DA, and 40DA models only)
The mid PTO safety switch, 1, is a double-pole,
single throw-style switch located on the control lever 1
pivot bracket. The switch, consisting of a rubber-
booted, push-button actuator and four rubber coated
terminals, monitors the position of the mid PTO
linkage and is activated by the mid PTO lever.
Removal
the negative (--) battery terminal. 2
3. Disconnect the mid PTO safety switch from the 10998387
wiring harness. 53
4. Remove the two switch mounting bolts, 2, and
pull the switch away from the tractor differential
housing.
Testing
mid PTO safety switch for electrical continuity.
Extended Position
With the mid PTO safety switch in the “extended”
position, continuity should not exist between any of
the four terminals. If continuity exists between any of
the four terminals while the switch is in the “extended”
55-29
Retracted Position
Using an ohmmeter, touch one of the test probes to
terminal, A. Touch the other test probe to terminal, B.
1. Push the switch to the retracted position.

continuity exists between terminal, A, and
terminal, B. If continuity does not exist between
terminal A, and terminal, B, the switch is
30002195
54
3. Using an ohmmeter in the same matter, touch
one of the test probes to terminal, C. Touch the
other test probe to terminal, D.
continuity exists between terminal, C, and
terminal, D. If continuity does not exist between
terminal, C, and terminal, D, the switch is
30002196
55
Op. 55 408
SEAT SAFETY SWITCH

The seat safety start switch, 1, is a single pole,
push-button type switch located underneath the
operator seat. When the operator is not seated, the
switch contacts are open and will not allow the tractor
to start. When the operator is seated, the switch
contacts are closed, allowing the tractor to start.
NOTE: The seat safety switch is non-adjustable.
1
10998317
56
55-30
Removal
NOTE: The seat safety start switch may be tested by
separating the switch leads, 1, under the seat,
hooking up ohmmeter test probes to the seat switch
leads and pushing down on the middle of the seat to
check for switch continuity. However, it is strongly
recommended that the switch be removed for 1
continuity testing.

2
the battery. 30997564
3. Raise the operator’s seat to reveal the seat
57
safety switch.
4. Disconnect the seat safety start switch leads, 1,
from the wiring harness. Lower the operator’s
seat.
5. Release the locking tabs to remove the switch
from the seat and remove the switch leads, 1,
from the switch, 2.
Testing
seat safety start switch for electrical continuity.
Extended Position
With the seat safety start switch in the “extended” (out)
position, continuity should not exist between the two
switch leads. If continuity exists between the switch
leads while the switch is in the “extended” position, the
seat safety start switch is defective and needs
replaced.
30003985
58
Retracted Position
With the seat safety start switch in the “retracted” (in)
position, continuity should exist between the two
switch leads. If continuity does not exist between the
switch leads while the switch is in the “retracted”
30002203
59
55-31
Op. 55 408
PARKING BRAKE SAFETY SWITCH

The parking safety switch, 1, is a double-pole, single
throw-style switch located on the brake control lever
pivot bracket. The parking brake switch is located
beneath the left operator’s platform on D35, D40,
D45 models only.
Testing
1
parking brake safety switch for electrical continuity.
Extended Position (Not Shown)

1. With the parking brake safety switch in the 30002202
“extended” (“off”) position, continuity should not
exist between any of the four terminals. If 60
continuity exists between any of the four
terminals while the switch is in the “extended”
position, the switch is defective and needs
replaced.
Retracted Position
1. Push the parking brake safety switch into the

“retracted” position.
30002195
61
to terminal, C. Touch the other test probe to
terminal, D.
30002196
62
55-32
RELAYS
1 2
3 4 5
13
7 8 14
6
10 11 12
9
10043894
63
(DX) Series Relay Panel Identification
1. HST “LOW” Range Relay 8. Glow Plug Lamp Relay
2. HST Cruise Control Relay 9. Glow Plug Timer
3. Flasher Relay 10. Front Lights Relay
4. Auxiliary Work lights Relay 11. Neutral Start Relay
5. HST “HIGH” Range Relay 12. Glow Plug Power Relay
6. Fuel Shutoff Relay 13. Safety Module
7. PTO Safety Relay 14. Diode
55-33
1 2
10
3 4 13
5
7 8 9
10043899
64
(D) Series Relay Panel Identification
1. Flasher Relay 6. Glow Plug Timer
2. Auxiliary Work lights Relay 7. Front Lights Relay
3. Fuel Shutoff Relay 8. Neutral Start Relay
4. PTO Safety Relay 9. Glow Plug Power Relay
5. Glow Plug lamp Relay 10. Safety Module
55-34
Relays are used on the D(DX) series tractors to
automatically complete (close) a circuit. The relays
are located under the left side of the dash cover,
behind the tractor’s firewall. A relay contains two
parts of a circuit. One part, the control circuit, uses
current to energize a coil. The other part, the function
circuit, is a switch. When energized, the coil of a relay
becomes an electromagnet opening or closing a
single circuit or directing current from one circuit to
another, depending on the type of relay.
DX deluxe model tractors utilize ten relays and

economy model tractors use six relays. There are four
different relays used on the D(DX) series tractors.
The function circuits are normally open when no
current is being supplied to the coil. If a circuit with
an SPST relay is energized with current on the
D(DX) series tractor, the switch becomes closed
and the circuit is completed. The relay is then
considered to be latched.
65
TESTING-MICRO RELAYS
“HI”, “LOW”, CRUISE CONTROL, FUEL
SHUTOFF, PTO SAFETY, AND GLOW PLUG
LAMP RELAYS
Replacement
1. Remove the relay suspected of being faulty from
the tractor to test.
2. Using an ohmmeter, touch one test probe to
terminal 3 and the other test probe to terminal 4.
3. Observe the ohmmeter. There should be little or
no resistance, indicating continuity. If there is no
continuity, the relay is defective and needs 30004390
replaced.
66
55-35
4. If the previous test showed continuity, touch one
ohmmeter probe to terminal 1 and the remaining
read approximately 79.5 ohms. If the reading is
not as specified, the relay is defective and needs
replaced.
20004391
67
6. If the results from the previous test were good,
use a jumper lead to connect the positive (+)
terminal of a 12-volt power source to terminal 1
of the relay. Use a jumper lead to connect the
negative (--) terminal of a 12-volt power source to
terminal 2 of the relay. The relay should now
energize.
7. Using an ohmmeter touch a test probe to terminal
3 of the relay. Touch the other ohmmeter test
no resistance, indicating continuity. If there is no 20004392
continuity, the relay is defective and needs
replaced. 68
HEADLIGHT AND NEUTRAL START

RELAYS
Replacement
terminal 87A and the other test probe to terminal
30.
replaced.
69
55-36
4. Repeat the previous test for terminal 30 and 87.
There should be no continuity between these
terminals. If tests indicate continuity, the relay is
energize.
probe to terminal 87. 70
replaced.
8. While the 12-volt power source is still connected,
touch an ohmmeter test probe to terminal 30 and
terminal 87A. There should be high resistance
indicating no continuity between the terminals. If
there is continuity, the relay is defective and
needs replaced.
71
55-37
GLOW PLUG POWER RELAY

Replacement
1. Remove the glow plug power relay from the
tractor.
terminal 87 and the other test probe to terminal
30.
3. Observe the ohmmeter. There should be high
resistance between these terminals, indicating
no continuity. If tests indicate continuity, the relay
is defective and needs replaced. 30004023
72
energize.
replaced. 73
55-38
DIODES
There are three separate diodes used on the “DX”
and “D” series tractors.
1. Diode Block used for HST “High” range (DX
models only)
(Located in relay panel)
10043894
74
2. HST cruise control diode (DX models only)
(Located below relay panel, tied to wire harness)
10043900
75
3. Rear PTO stationary operation diode (All
models)
(Located underneath the left rear operators 3
platform, tied to wire harness)
Diodes are electrical devices which current is

allowed to pass in one direction, directing current
within a circuit. Diodes allow the use of one wire
within multiple circuits to control current flow to
electrical components, such as relays. The (DX)
model tractors utilize four diodes to direct current. 10043901
Two of these diodes are paired together in one case,
referred to as a diode module. The “D” series tractors 76
only have one diode in the tractor harness.
55-39
Module Testing
1. Remove the diode module suspected of being
faulty from the tractor.
NOTE: For this test, an electrical multimeter with
diode test capabilities may be used in place of an
ohmmeter. If a multimeter with diode testing
capabilities is unavailable, use an ohmmeter to test
as described below.
2. Using an ohmmeter, touch the red, positive (+),

test probe to diode terminal “1”. Touch the black,
negative (−), ohmmeter test probe to diode
terminal “2”. Observe the ohmmeter.
3. The ohmmeter should show high resistance,
indicating no continuity and that current is not
flowing through the diode in that direction. If there
is continuity. Check to see that the test probes
are on the correct terminals, and if they are, the
diode module is defective and needs replaced.
30004050
77
4. If the previous test indicated the diode was
functioning properly, touch the red, positive (+),
ohmmeter test probe to terminal “2” of the diode
and the black, negative (--), test probe to terminal
“1” of the diode.
show little or no resistance, indicating continuity
in that direction. If the ohmmeter does not show
continuity, the diode module is defective and
needs replaced.
30004051
78
55-40
6. Repeat the test outlined in steps 2 through 5, to
test terminals 3 and 4 of the diode module.
Replace the diode module if test determine the
diode module to be defective. The diode should
show continuity only when red, positive (+),
positive test probe is touching terminal 4 and the
black negative (--) test probe is touching terminal
3.
20002218
79
Diode Testing
Use an ohmmeter to test the diodes.
Connect the ohmmeter leads to the diode terminals

and observe the meter reading, then reverse the
ohmmeter leads and observe the meter reading.
• Continuity should exist in one direction only.
If there is continuity in both directions, or if there is no

continuity in either direction, replace the faulty diode.
Power should flow in a positive to negative direction.
80
55-41
OPERATOR SAFETY MODULE

The operator safety module, 1, is part of the tractor
safe operation circuit. When the operator safety
module is energized it allows the ground circuit for
the control portion of the fuel shutoff solenoid relay to
be completed. If current no longer flows to the 1
operator safety module, the ground circuit for the
relay becomes open. This causes the fuel shutoff
solenoid relay to become non-energized. When the
relay becomes non-energized, the current to the fuel
shutoff solenoid is discontinued, stopping the tractor
engine. Current is supplied to the operator safety
module when the operator is seated, or when the
PTO is disengaged and the parking brake is applied. 10043894 HST
The operator safety module, 1, is located under the
left side of the dash cover, behind the tractor’s 81
firewall.
Removal
10043899
Gear
82
30003983
83
55-42
4. Remove the left side cover to reveal the
relay/diode panel.
5. Release the locking tabs on the operator safety
module to disconnect the module from the wire
harness.
1
30002142
84
Testing
test probe to module terminal “B”. Touch the
black, negative (−), ohmmeter test probe to diode
terminal “C”. Observe the ohmmeter.
flowing through the operator safety module. If
there is continuity. Check to see that the test
probes are on the correct terminals, and if they
are, the operator safety module is defective and
needs replaced.
30004053
85
3. If the previous test indicated the operator safety
module was functioning properly, clamp the red,
positive (+), ohmmeter test probe to terminal “B”
of the safety module and the black, negative (−),
test probe to terminal “C” of the Safety module.
CAUTION
Only apply battery current to the operator safety
control module for 3--5 seconds or damage will
occur.
4. Connect a jumper wire from terminal “E” on the

operator safety module to the positive (+) 30004048
terminal of a 12-volt power supply. 86
5. Connect a jumper wire to terminal “B”.
6. While observing the ohmmeter, touch the jumper
wire to terminal “B’ from the negative (--) terminal
of the 12-volt power supply. There should be little
or no resistance, indicating continuity. If the
reading shows high resistance, the operator
safety module is defective and needs replaced.
55-43
GLOW PLUG TIMER

The glow plug timer, 1, is an electronic timer that is
located under the left side of the dash cover, behind
the tractor’s firewall. The timer controls how long the
glow plugs and the indicator light on the instrument
panel remain supplied with current when the key
switch is turned form the “OFF” position to the
“ACC/RUN” position. The glow plug timer delays the
glow plugs and indicator light on deluxe model
tractors for 4-5 seconds and for 10-11 seconds on the
economy model tractors. The glow plug timer
controls the glow plug and indicator light circuit by
1
supplying or cutting the ground path to the glow plug
power relay’s coil circuit. 10043894 HST
87
10043899 Gear
88
55-44
Testing
the battery.
2. Remove the bolt retaining the light timer to the
tractor and disconnect the timer from the main
wiring harness.
NOTE: The terminals are not number or letter coded
on the light timer. 1
2
3. Connect a jumper wire from terminal “C” on the
timer, 1, to the positive (+) terminal of a 12-volt
power supply.
4. Connect a test light, 2, from terminal “A” of the
timer, 1, to the positive (+) terminal of a 12-volt -- +
C
power supply. A
D
B
E
12 VOLTS
5. Connect a jumper wire from terminal “D” of the

timer, 1, to the negative (--) terminal of the 12-volt
power supply. Observe the test light, 2. 20000874
6. The test light should illuminate for approximately 89

4 – 5 seconds for the deluxe models and 10-11
seconds for economy models, then turn off. If the
test light fails to illuminate or does not turn off
after the specified time, the timer is defective and
needs replaced.
7. Connect the negative (−) battery cable to the
battery.
Op. 55 201
1
ENGINE GLOW PLUGS
The engine glow plugs, 1, are located on the right
side of the engine cylinder head, below the fuel
injectors. The glow plugs are used to preheat the air
in the pre-combustion chamber. This aids in the
starting of the engine when cold.
10000896
90
55-45
The glow plugs utilize a heating element that is
contained in a stainless steel sheath, 1. The coiled
heating wire, 2, is sintered into magnesium oxide 1 2
powder, 3. The magnesium oxide powder is used to 4
evenly transfer heat to the stainless steel sheath,
which heats the air in the combustion chamber. The
magnesium oxide powder is also used to insulate the
heating wire from the outer sheath and glow plug
body.
The glow plug heats when electrical current is 3

passed from the glow plug electrode, 4, to one end
of the heating wire, 2. Electrical resistance warms the
heating wire when electrical current is flowing
through the wire. The opposite end of the wire is 91
connected to the sheath. The sheath and glow plug
body, 5, are grounded by the engine block.
NOTE: All deluxe (DX) tractors utilize a fast heating

type glow plug (marked Y-701RS). All economy
model (D) tractors utilize a slower heating glow plug
(marked Y-107 V glow plug).
Removal
1. Disconnect the negative (−) battery cable from
the battery.
2. Remove the electrode nuts, 1, the electrical
connector, 2, and washers securing the 1
electrode bus bar, 3, to the glow plugs.
3. Remove the glow plug(s) from the engine
cylinder head.
10000896 3
92
55-46
Testing
1. Remove carbon from the sheath end of the glow
plug.
NOTE: Do not test resistance using the glow plug
sheath.
2. Using an ohmmeter, touch one test probe to the
glow plug electrode, 1. Touch the other test probe
to the glow plug body, 2.
3. Observe the ohmmeter reading, a resistance
reading of 0.8 ohms maximum is normal for the
(DX) deluxe model tractor glow plugs. A
resistance reading of 1.0 ohms maximum is
normal for (D) economy model tractor glow 1 2
plugs. If the resistance is too high, the glow plug
is defective and needs replaced.
20000876
93
Installation
1. Thread the glow plugs into the engine cylinder 2
head. Torque each glow plug to 10 – 15 N⋅m (11.0
– 14.5 ft. lb.).
2. Install the electrode bus, 1, and the washers onto
the glow plugs. Secure with the three (3) nuts, 2.
3. Connect the electrical connector, 3, to the wire
harness.
4. Connect the negative (--) battery cable to the 3
battery.
10000896
1
94
55-47
HAZARD FLASHER/TURN SIGNAL

CONTROL MODULE
The hazard flasher/turn signal control module, 1, is
located underneath the steering column mounting
bracket. The control module controls current flowing
to the hazard flasher/turn signal lights on the rear
fenders. Refer to the chart below for the functions of
the control module.
1
10043900
95
HAZARD/TURN SIGNAL RESULT

SWITCH POSITION
Hazard switch “On” Both flashers blink in unison.
Left turn signal “On” Left flasher and taillight blink and right flasher and taillight
remain solid.
Right turn signal “On” Right flasher and taillight blink and left flasher and taillight
remain solid.
55-48
Removal
2. Raise the tractor hood.

20003983
96
5. Unplug the connector from the control module, 1.
10043900
97
7. Remove the left side cover to reveal the
relay/diode panel.
30002142
98
55-49
Testing 2. Connect a jumper wire to terminal 4 of the control
Use a 12 volt power source, a suitable switch, jumper module and to the positive (+) terminal of a test
wires and test lights to perform the 3 tests on the light. This test light will simulate the right flasher.
hazard flasher /turn signal control module. Connect the negative (--) terminal of the test light
to the negative (--) terminal of the power source.
NOTE: Disregard terminal markings on the module. 3. Connect a jumper wire to the positive (+) terminal
Refer to terminal markings in the illustration. of the power source and the switch.
Test 1 – Test 1 is used to verify that the control 4. Connect a jumper wire to the switch and terminal
module is supplying power to both of the hazard 2 on the control module.
lights. This test simulates the hazard switch being
5. Connect a jumper wire to the positive (+) terminal
turned to the “On” position.
of the power source and to terminal 1 of the
control module.
1. Connect a jumper wire to terminal 3 of the control
module and to the positive (+) terminal of a test 6. Connect a jumper wire to the negative (--)
light. This test light will simulate the left flasher. terminal of the power source and to terminal 6 of
Connect the negative (--) terminal of test light to the control module.
the negative (--) terminal of the power source. 7. Move the switch to the “On” position, observe the
two test lights. Both should flash on and off
simultaneously.
20023430
99
55-50
Test 2 – Test 2 is used to verify that the control 4. Connect a jumper wire to terminal 3 of the control
module is functioning properly when the left turn module and to the positive (+) terminal of a test
signal is activated. This test simulates the turn signal light. This test light will simulate the left flasher
switch being turned to the “Left” position. (amber). Connect a jumper wire to the (--)
negative terminal of the test light and to the
1. Connect a jumper wire to terminal 10 of the negative (--) terminal of the power source.
control module and to the positive (+) terminal of 5. Connect a jumper wire to the positive (+) terminal
a test light. This test light will simulate the left of the power source and the switch.
taillight (red). Connect a jumper wire to the (--)
negative terminal of the test light and to the 6. Connect a jumper wire to the switch and terminal
negative (--) terminal of the power source. 8 on the control module.
2. Connect a jumper wire to terminal 11 of the 7. Connect a jumper wire to the positive (+) terminal
control module and to the positive (+) terminal of of the power source and to terminal 1 of the
a test light. This test light will simulate the right control module.
taillight (red). Connect a jumper wire to the (--) 8. Connect a jumper wire to the negative (--)
negative terminal of the test light and to the terminal of the power source and to terminal 6 of
negative (--) terminal of the power source. the control module.
3. Connect a jumper wire to terminal 4 of the control 9. Switch the switch to the “On” position, observe
module and to the positive (+) terminal of a test the two test lights. The left flasher and the left
light. This test light will simulate the right flasher taillight should both flash on and off while the
(amber). Connect a jumper wire to the (--) right flasher and right taillight remain lit (solid).
negative (--) terminal of the power source.
20023431
100
55-51
module is functioning properly when the right turn module and to the positive (+) terminal of a test
switch being turned to the “Right” position. (amber). Connect a jumper wire to the (--)
module and to the positive (+) terminal of a test the two test lights. The right flasher and the right
light. This test light will simulate the right flasher taillight should both flash on and off while the left
(amber). Connect a jumper wire to the (--) flasher and left taillight remain lit (solid).
20023432
101
55-52
Installation
1. Plug the tractor wire harness connector into the
control module, 1.
10043900
102
2. Install the left side rear panel onto the tractor.
4. Lower and secure the tractor hood.
55-53
Op. 55 410
FUEL LEVEL SENDING UNIT 1

The fuel level sending unit, 1, is mounted on top of the
fuel tank and extends into the tank. The sending unit
utilizes a float the raise and lowers with the fuel level
inside the tank. The float regulates a variable
resistance to ground, which translates into move-
ment of the fuel gauge on the instrument panel. As
the float lowers (fuel being consumed) inside the
tank, the ground resistance increases, indicating
less fuel on the fuel gauge.
30002209
103
Removal
the battery.
3. Disconnect the fuel level sending unit from the
wiring harness.
4. Remove the two screws, 1, to remove the fuel
level sending unit cover, 2.
1
2
30002210
104
5. Remove the five (5) retaining screws, 1, that
secure the sending unit, 2, to the fuel tank.
1
10043896
105
55-54
6. Carefully remove the sending unit, 1, from the
fuel tank.
1
7. Remove and discard the sealing gasket, 2, from
the sending unit, 1.
30002211
106
Testing
terminal “A” of the sending unit, touch the other
test probe to terminal “B” of the sending unit.
Observe the reading on the ohmmeter.
2. With the sending unit float in the down position
(tank empty), the ohmmeter should indicate
between 248 -- 252 ohms. If the ohmmeter reading
is not within these specifications, the sending unit
is defective and needs replaced.
30004010
107
3. With the sender in the up position (tank full), the
ohmmeter should indicate between 28 -- 32 ohms.
If the ohmmeter reading is not within these
specifications, the sending unit is defective and
needs replaced.
30004011
108
55-55
Installation
1. Install a new sealing gasket, 2, between the
sending unit, 1, and the fuel tank. 1
2. Carefully place the sending unit, 1, into the fuel
tank.
30002211
109
3. Secure the sending unit, 2, to the fuel tank using
the five (5) retaining screws, 1.
1
10043896
110
4. Install the fuel level sending unit cover, 2, using
the two screws, 1.
1
5. Connect the fuel level sending unit to the wiring 2
harness.
battery.
30002210
111
55-56

The fuel shutoff solenoid, 1, is located on the right
side of the engine, threaded into the rear of the fuel
injection pump, 2. The fuel shutoff solenoid contains
a spring-loaded plunger that pushes the injection
pump control rack to the closed (shut-off) position 2
when the solenoid is not energized. When the key
switch is turned to the “ACC/RUN” or “START”
position, the safety stop relay closes completing the 1
circuit that energizes the solenoid. This retracts the
plunger from the injection pump, and the injection
pump control rack moves into the position that allows
the engine to start.
112
Removal
the battery.
2. Disconnect the wiring harness lead from the fuel
3. Using a pair of pliers, carefully remove the fuel
shutoff solenoid, 1, from the fuel injection pump,
2
2.
113
4. Remove and discard the sealing washer, 1,
which seals the solenoid, 2, to the fuel injection
pump.
1
20000885
114
55-57
Testing
1. Using a suitable measuring device, measure the 1
actuating pin, 1, protrusion distance, “A”, on the
solenoid. The distance should measure between
25.5 - 26.4 mm (1.004 - 1.040 in.). If the distance
is not within these specifications, the solenoid is
115
NOTE: When connecting the 12-volt power supply to
the solenoid body, be sure paint is the removed from 3
the body. Otherwise, the power will not be transferred
to the solenoid.
2. Use jumper wires to connect the positive (+)

terminal of a 12-volt power supply to the solenoid
lead, 1. Connect the negative terminal of the 1
12-volt power supply to the solenoid body, 2. The
plunger should retract into the solenoid body. 2
3. Using a suitable measuring device, measure the
actuating pin, 1, protrusion distance, “B” on the
11.5 -14.5 mm (0.453 - 0.571 in.). If the distance 116
is not within these specifications or the plunger
does not retract, the solenoid is defective and
needs replaced.
Installation
1. Install a new sealing washer, 1, on the solenoid,
2.
20000885
117
55-58
2. Thread the fuel shutoff solenoid, 1, into the fuel
injection pump, 2. Use pliers to tighten the
solenoid into the injection pump.
3. Connect the wiring harness lead, 3, into the fuel
shutoff solenoid, 1. 2
battery. 1
118
Op. 55 414
1
ENGINE OIL PRESSURE SWITCH
The oil pressure sender, 1, is located on the top front
side of the engine. The switch opens under normal oil
pressure (above 6 PSI) and closes when oil pressure
is low (below 6 PSI) to complete the ground circuit of
the oil pressure warning light.
When the ground circuit is completed, the oil pressure

warning light illuminates on the instrument panel
when the key switch is turned to the “ON” position and
goes out when the engine is started. If the light does
not go out after the engine has started, first check the
engine oil level. If oil level is correct, check for a 119
malfunctioning sender or engine oil pump.
Testing
1. Using an ohmmeter, touch one test lead to the
pressure switch terminal, 1, and the other test
lead to the switch body, 2. 3
2. Observe the ohmmeter. There should be little or 1
no resistance, indicating continuity in the switch.
If there is no continuity, the switch is defective
and needs replaced.
NOTE: The following test is not a calibrated test. The
purpose of the test is to see if the switch opens at
pressure. 2
20000880
1. While the test leads are connected to the switch,
pressurize the switch oil pressure port, 3, with 120
low pressure (10 -- 30 psi) compressed air.
2. Observe the ohmmeter. While air pressure is
being supplied to the oil pressure port, the
ohmmeter should indicate high resistance, or no
continuity. If there is continuity, the switch is
CAUTION
Do not use high pressure compressed air for the
following test, otherwise damage may occur to
the oil pressure switch.
55-59
ENGINE COOLANT TEMPERATURE

1
SENDING UNIT
The coolant temperature sender, 1, is located at the
left front side of the engine inside the thermostat
housing. This sender regulates a variable resistance
to ground, which translates into the movement of the
temperature gauge.
121
Testing
WARNING
Do not perform sending unit test with tractor
engine running. Contact with moving parts will
cause bodily injury.
NOTE: Engine paint must be removed from sending

unit body or the ohmmeter will indicate a false
reading when the ohmmeter test lead is touched to
sending unit body.
1. Disconnect the main wiring harness terminal, 2,
from the coolant temperature sending unit. 2
122
55-60
sending unit terminal, 1. Touch the other test lead 1
to the sending unit body, 2.
∞ 0
123
3. Observe the ohmmeter for resistance readings Coolant Temperature Sending Unit Temperature
at different engine operating temperatures. If
resistance is too high, the sending unit us 35° C (95° F) 670.0 ± 80 ohms
defective and needs replaced. 80° C (176° F) 118.0 ± 6 ohms
105° C (221° F) 54.5 ± 2.7 ohms
115° C (239° F) 42.0 ± 2.5 ohms
55-61
HI/LOW TRANSMISSION RANGE SWITCH

(HST)
The transmission range control switch, 1, is a
two-way momentary switch located on the right 1
control pod on the tractor. This switch changes the
hydraulic range of the transmission hydraulic pump.
The switch contains two bulbs that illuminate,
indicating what hydraulic range the transmission
hydraulic pump is in, “HI” (rabbit) or “LOW” (turtle).
When the switch is pushed to the “HI” range, current
is supplied to the transmission range solenoid, which
changes the position of the swash plate in the
hydraulic pump, increasing hydraulic oil flow. The
solenoid is not energized in the “LOW” position and
the transmission pump operates at normal hydraulic 10998318
oil flow. The “LOW” transmission setting is the default
setting, meaning the tractor will reset to the “LOW” 124
position when the tractor engine is shut off and
restarted.
The tractors may also be equipped with an optional
joystick switch, 1, that is mounted on the optional 1
two-spool remote valve.
10998370
125
Testing
1. Carefully pry the range switch, 1, from the right
1
control pod.
2. Disconnect the tractor wiring harness from the
switch.
10998318
126
55-62
terminal 9. Touch the other test probe to terminal
10.
4. Observe the ohmmeter. There should be
approximately 19.0 ohms of resistance between
the terminals. If resistance is high or off scale, the
“LOW” indicator light is faulty and the switch
needs replaced.
30004025
127
5. Repeat the test for terminals 7 and 8 for the “HI”
range indicator light. Replace the switch if test
results are not within the limit specified.
30004026
128
6. Hold the switch to the “LOW” (turtle) position.
Touch one ohmmeter test probe to terminal 2.
Touch the remaining ohmmeter test probe to
terminal 1.
no resistance, indicating continuity. If the reading
shows high resistance, the switch is defective
and needs replaced.
30004027
129
55-63
8. Hold the switch in the “HI” (rabbit) position. Touch
one ohmmeter test probe to terminal 2. Touch the
other ohmmeter test probe to terminal 3.
and needs replaced.
10. If the switch is good, connect the wiring harness
to the switch and push the switch back into the
tractor control pod.
30004028
130
Optional Testing
1. Disconnect the range switch connector, 1, from
the wiring harness. Remove the two (2) screws, 2, 2
retaining the switch to the front remote valve
joystick. 1
20003787
131
2. Using an ohmmeter, connect one test probe to
terminal “C”. Connect the other test probe to
A B
terminal “A”.
3. Press the “HI” (rabbit) button and observe the
ohmmeter. The ohmmeter should show little or no
resistance, indicating continuity. If the ohmmeter
shows high resistance, the switch is defective and
needs replaced. C
4. Press the “LOW” (turtle) button and observe the
ohmmeter. The ohmmeter should show high
resistance, indicating no continuity. If there is
continuity, the switch is defective and needs 30004054
replaced.
132
55-64
terminal “C”. Connect the other test probe to A
terminal “B”.
6. Press the “LOW” (turtle) button and observe the B
C
needs replaced.
replaced.
133
8. To replace the switch, remove the joystick cover
retaining screw, 1, then pull the switch out.
1
10998370
134
HI/LOW TRANSMISSION RANGE SOLENOID

(HST)
Deluxe model DX series tractors are all equipped
with a dual, “HI/LOW” range hydrostatic transmission
(HST). The transmission utilizes an electronic
transmission range solenoid, 1, to change the swash
plate angle within the transmission hydraulic oil
pump to “HI” range. This increases hydraulic oil flow
through the transmission. When the transmission is
in “LOW” range the solenoid is not energized and the
solenoid retracts, allowing the swash plate to return
to normal operating angle, reducing hydraulic oil flow
in the transmission. The transmission range solenoid
is located in a housing on the left side of the
transmission housing. 30002884 1
135
55-65
Removal
the battery.
NOTE: When removing the solenoid valve body from
the transmission, be sure not to lose the three (3) o
rings, 1, that are located in the solenoid valve body
and the transmission case adapter block.
1
30002887
136
2. Disconnect the solenoid leads, 3, from the tractor
wiring harness.
3. Remove the four (4) 5mm hex head mounting
bolts, 1, securing the solenoid valve body, 2, to
the transmission housing. Remove the solenoid
valve body from the transmission adapter block.
2 3
30002884 1 1
137
Testing
2
1. Remove the solenoid assembly, 1, from the
solenoid valve body, 2. Be sure not to lose any
parts.
1
30002889
138
55-66
2. Connect an ohmmeter test lead to each of the
solenoid terminals.
indicate a resistance of approximately 7.5 -- 10.5
ohms.
4. If the reading is not within this specification, the
solenoid is defective and needs replaced.
30000740
139
5. Connect a positive (+) lead from a 12-volt power
source to one of the solenoid terminals, 1.
1
6. Connect the negative (--) lead from the 12-volt
power source to the remaining solenoid terminal.
7. Observe the solenoid. The solenoid plunger, 2,
should extend when voltage is applied. If the
plunger does not extend, the solenoid is
defective and need replaced. 2
8. Disconnect the 12-volt power source from the
solenoid. The plunger should retract immediate-
ly. If the plunger does not retract, the solenoid is
defective and needs replaced. 30003061
9. If the solenoid is good, install the solenoid 140

assembly back into the solenoid valve body.
Installation
1. Install the solenoid valve assembly, 1, to the
1
transmission adapter plate and secure with the
four (4) 5mm hex head bolts, 2.
2. Connect the solenoid leads, 3, to the tractor
wiring harness.
battery.
2 2 3
30002884
141
55-67
ELECTRIC CRUISE CONTROL SWITCH

1
(HST)
The electric cruise control switch, 1, is located on the
right control pod. The cruise control switch controls
current to cruise control magnet. Cruise control is
used to maintain the tractor at a constant speed
forward or backward. When the cruise control switch
is pushed from the “OFF” position to the “SET”
position, the control circuit of the cruise control relay
is energized. This closes (completes) the function
circuit of the relay, which supplies power to the cruise
control magnet. When the cruise control switch is
released from the “ON” position, the switch rockers 10998318
to the “ON” position, which keeps the cruise control 142
activated until the switch is pushed to the “OFF”
position or the brake pedal or hand brake is engaged.
Current to the cruise control relay is interrupted when
either brake is engaged, which deactivates the cruise
control magnet. The cruise control switch is
equipped with an indicator light that will illuminate
when the switch is moved to the “SET” and “ON”
position, indicating the cruise control has been
activated.
Removal
the battery.
2. Carefully pry the switch from the control pod.
3. Disconnect the electric cruise control switch from
the wiring harness.
55-68
143
Testing placed in any of its three positions). The reading
Remove the switch from the wiring harness. should be between 55 ohms and 60 ohms.
NOTE: The switch terminals are identified on the NOTE: The light is not serviced separately. If it does
back of the switch. Numbers 1 and 4 are blank. not illuminate, replace the switch.
Using an ohmmeter, depress the switch to the “SET” Replace the switch if the correct readings are not
position and connect the ohmmeter leads across obtained during testing.
terminals 5 and 6, then across terminals 2 and 3. If
continuity exists across these terminals, the switch is
operating properly. Installation
1. Connect the electric cruise control switch to the
Next place the switch in the “ON” (middle) position
wiring harness.
and connect the ohmmeter leads across terminals 2
and 3. If there is continuity, the switch is good. 2. Push the cruise control switch, 1, into the right
control pod.
To test the internal light bulb, connect the ohmmeter
leads across terminals 7 and 8 (the switch may be
55-69
CRUISE CONTROL MAGNET (HST)

The cruise control magnet, 1, is located under the
right tractor fender and is attached to the hydrostatic 3 4
transmission (HST) linkage. The cruise control
magnet is a simple electromagnet. When the cruise
control switch is activated, current is supplied to the
cruise control magnet and the magnet locks the HST
control linkage in place. This maintains a constant
transmission speed, which translates to a constant
tractor ground speed, forward or reverse.
Removal 2 1
1. Disconnect the negative (--) battery cable from 30003789
the battery.
144
2. Disconnect the main wiring harness connector,
2, from the cruise control magnet, 1.
3. Remove the two bolts, 3, which secure the cruise
control magnet mounting bracket, 4, to the
transmission. Remove the magnet from the
tractor.
55-70
Testing
Use an ohmmeter to test the cruise control magnet. ∞ 0
1. Disconnect the magnet from the tractor wiring
harness and connect the ohmmeter leads to the
two leads coming from the magnet.
• A meter reading of 11-12 ohms is normal.
145
2. Disconnect the ohmmeter from the magnet and
apply 12 volts across the magnet leads.
• The surface will become magnetized and
attract any ferrous object if the cruise control
magnet is working properly.
- +
If test results are not as outlined above, replace the
cruise control magnet.
146
Installation
3 4
1. Install the cruise control magnet, 1, and mounting
bracket, 4, to the tractor transmission and secure
the mounting bracket, 4, to the transmission
using the two bolts, 3.
2. Connect the main wiring harness connector, 2, to
the cruise control magnet.
battery.
2 1
20003789
147
55-71
CRUISE CONTROL BRAKE RELEASE

SWITCH (HST)
The HST cruise control brake release switch, 1, is a
push-button switch located beneath the left
operator’s platform. The actuator button and the
terminals of this switch are sealed to protect the
switch from moisture. The switch is normally
retracted (in), which completes the ground circuit and
allows current to flow through the switch. When the
brake pedal is applied, the actuator button is
released and the switch is opened; which interrupts
the ground path through the switch. The cruise
control brake release switch is standard on the 1
deluxe models.
20004015
148
Removal
2. Disconnect the wiring harness, 2, from the cruise
control brake release switch, 1.
3. Remove the two screws, 3, to remove the cruise
control brake release switch, 1, from the tractor.
Testing 3 2
Use an ohmmeter to test terminals of the cruise
control brake release switch for electrical continuity. 30002198
NOTE: The cruise control brake release switch 149

wiring harness only makes contact with terminals, A,
and, D. Terminals, B, and, C, are not used.

1. With the cruise control brake release switch in
the “extended” position, continuity should not
exist between terminals, A, and, D. If continuity
exists between terminals, A, and, D, while the
switch is in the “extended” position, the switch is
55-72
Retracted Position
to terminal, A. Touch the other test probe to
terminal, D.
terminal A, and terminal, D, the switch is
30002197
150
Installation
1. Install the cruise control brake release switch, 1, 1
using the two screws, 3.
2. Connect the wiring harness, 2, to the cruise
control brake release switch, 1.
3 2
30002198
151
55-73
55-74
Chapter 2 -- Schematics
CONTENTS

Complete Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Start Circuit (Operator Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Safety Start Circuit (Operator Not Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safe Operation Circuit (Operator Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safe Operation Circuit (Operator Not Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Road Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Hazard Flasher Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PTO Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Engine Coolant Temperature Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Engine Low Oil Pressure Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fuel Level Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Parking Brake Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Tachometer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
HST Range “LOW” Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
HST Range “HIGH” Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
55-1
55-2
55-3
55-4
55-5
55-6
55-7
55-8
55-9
55-10
10
55-11
11
55-12
12
55-13
13
55-14
TO CONNECTOR C45
CAVITY 5B
PAGE 7
14
55-15
15
55-16
16
55-17
SAFETY START CIRCUIT (OPERATOR PRESENT)
60043902
55-18

NOTE: The starting circuit is shown with:
• Operator in the seat

• Parking Brake “OFF”
• Transmission range lever in “NEUTRAL” position
• PTO modulation lever in the “OFF” position
1. Current starts at the battery, and flows through the positive (+) battery cable to the engine starter motor.
2. From the starter motor, current flows through the 40-amp fuse to a wire splice. The wire splice sends current
into two directions:
• To the “B and “D” terminals of the ignition switch
• To terminal 30 of the glow plug power relay
3. When the ignition switch is placed in the “START” position current is transferred across the following ignition
switch terminals:
• “B” to “C” terminals
• “D” to “A” terminals
Terminal “A” of ignition switch

1. Current flows from the “A” terminal of the ignition switch to 86 terminal of the neutral start relay.
Terminal “C” of ignition switch

1. Current flows from the “C” terminal of the ignition switch to the fuse panel bussbar, from the bussbar current
travels through the 8-amp circuit breaker.
Safety Switches Operation

1. From the 8-amp circuit breaker current travels to a wire splice which directs the current into three different
safety switches:
• Neutral start
• Main PTO
• Operator Seat Switch
2. When the transmission range gear selector is in the neutral position the neutral safety start switch contacts
close, sending current to terminal #30 of the neutral start relay.
3. When the main PTO selector is placed in the “OFF” position the main PTO safety switch contacts close,
sending current to the coil side of the PTO safety start relay.
4. When the operator is in the seat, the operator seat safety switch contacts close, sending current to terminal
“E” of the operator safety module.
5. With current supplied to terminal “E” of the operator safety module, the module completes the ground path
through terminals” B”& “C” of the module. Terminal “B” of module provides completes the ground path for the
fuel shutoff relay.
55-19
Relays Operation
1. The PTO safety start relay has current provide to coil side of the relay by the main PTO safety switch. The
ground path is provide by the main tractor ground. When current and ground source provided the relay
energizes closing contacts 2-3 & 2-5. Terminal 2-5 provides the ground path to terminal # 85 of the neutral
start relay.
2. When the ground source is provide to terminal #85 of the neutral start relay and current provide to terminal
#86 from the “A” of the ignition switch, the relay latches terminals # 30 and #87. Terminal #87 provides current
to terminal #5 of the glow plug timer relay and to the starter solenoid allowing the engine starter to rotate the
engine.
3. Current is supplied to the fuel shutoff relay by the 8-amp circuit breaker and when the ground path is
completed by the “B” terminal of the operator safety module, the fuel shutoff relay energizes, allowing current
to flow to the fuel shutoff solenoid. When the solenoid is energized the solenoid plunger retracts and allows
fuel to flow to the fuel injection pump.
Glow Plugs Operation

1. The glow plug power relay is provided with current to terminal # 85 from the #1 (7.5 amp fuse) and terminal
#30 from 40-amp main fuse.
2. The glow plug timer relay has current supplied to terminal #5 and ground sourced to terminal #3, this
energizes the relay and latches terminals #6 & #3.
NOTE: Terminal #5 is on the backside of the timer, glow plugs and indicator light will not be timed during starting
cycle.
3. The #6 terminal of the glow plug timer relay provides the ground source for terminal #86 of the glow plug
power relay. With current provided to terminal #85 and ground to terminal #86, the glow plug power relay
energizes latching terminals #30 and #87 of the relay. Terminal #87 provides current to the glow plugs,
allowing the glow plugs to generate heat to aid in starting the engine.
4. Terminal #87 also provides current to the glow plug lamp relay. This current energizes the relay. When the
relay is energized terminals 3-5 & 3-3 are latched completing the ground circuit for the glow plug indicator
light in the instrument panel, terminal #7, and with the #5 (7.5 amp fuse) supplying current to terminal #2 of
the instrument panel, allows the indicator light to illuminate.
55-20

TROUBLESHOOTING

Starter motor will not energize Insufficient battery charge Test battery. Charge, add water, or
replace as necessary
Defective 8-amp operator safety Inspect and replace circuit breaker

system circuit breaker as necessary
Blown 40 amp main fuse Inspect and replace main fuse as

necessary
Defective key switch Test key switch and replace as

necessary
Defective PTO safety start or Test relays and replace as neces-

neutral start relay sary
Malfunctioning safety start switch Test neutral range, main PTO, mid
PTO (if equipped) and seat safety
start switches for adjustment,
proper operation, and faulty ground
circuits
Malfunctioning starter motor Test starter motor and repair or

Starter motor energizes, but fails to Defective operator safety module Test module and replace as
start engine (lacks exhaust smoke) necessary
Defective fuel shutoff relay Test fuel shutoff relay and replace
as necessary
Malfunctioning fuel shutoff solenoid Test fuel shutoff solenoid and

Glow plugs will not energize Blown #1, 7.5 amp fuse Inspect and replace 7.5 amp fuse
as necessary
necessary
Defective glow plug timer or power Test relays and replace as
relay necessary
Corroded glow lug buss bar con- Check connection repair as needed
nection
Defective glow plugs Inspect and replace glow plugs as
necessary
Glow plug indicator light will not Blown #5, 7.5 amp fuse Inspect and replace 7.5 amp fuse
illuminate as necessary
Defective glow plug power or lamp Test relays and replace as
relay necessary
55-21
SAFETY START CIRCUIT (OPERATOR NOT PRESENT)
60043903
55-22

NOTE: The starting circuit is shown with:
• Parking Brake “ON”

• PTO modulation lever in the “OFF” position
• To the “B and “D” terminals of the ignition switch
• To terminal 30 of the glow plug power relay
switch terminals:

1. Current flows from the “A” terminal of the ignition switch to 86 terminal of the neutral start relay.

Safety Switches Operation

1. From the 8-amp circuit breaker current travels to a wire splice which directs the current into three different
safety switches:
• Neutral start
• Main PTO
• Parking Brake Switch
2. When the transmission range gear selector is in the neutral position the neutral safety start switch contacts
close, sending current to terminal #30 of the neutral start relay.
3. When the main PTO selector is placed in the “OFF” position the main PTO safety switch contacts close,
sending current to the coil side of the PTO safety start relay.
4. Current is sent from the neutral safety start switch to the mid PTO safety switch or jumper harness. With the
mid PTO in the “OFF” position the mid PTO safety switch closes or (jumper harness) sending current to the
park brake safety switch.
5. When the parking brake is “ON” the park brake safety switch is closed sending current to the stationary rear
PTO diode, this diode sends current to terminal “E” of the operator safety module.
6. With current supplied to terminal “E” of the operator safety module, the module completes the ground path
through terminals” B”& “C” of the module. Terminal “B” of module provides completes the ground path for the
fuel shutoff relay.
55-23
Relays Operation
1. The PTO safety start relay has current provide to coil side of the relay by the main PTO safety switch. The
ground path is provide by the main tractor ground. When current and ground source provided the relay
energizes closing contacts 2-3 & 2-5. Terminal 2-5 provides the ground path to terminal # 85 of the neutral
start relay.
2. When the ground source is provide to terminal #85 of the neutral start relay and current provide to terminal
#86 from the “A” of the ignition switch, the relay latches terminals # 30 and #87. Terminal #87 provides current
to terminal #5 of the glow plug timer relay and to the starter solenoid allowing the engine starter to rotate the
engine.
3. Current is supplied to the fuel shutoff relay by the 8-amp circuit breaker and when the ground path is
completed by the “B” terminal of the operator safety module, the fuel shutoff relay energizes, allowing current
to flow to the fuel shutoff solenoid. When the solenoid is energized the solenoid plunger retracts and allows
fuel to flow to the fuel injection pump.
Glow Plugs Operation

1. The glow plug power relay is provided with current to terminal # 85 from the #1 (7.5 amp fuse) and terminal
#30 from 40-amp main fuse.
2. The glow plug timer relay has current supplied to terminal #5 and ground sourced to terminal #3, this
energizes the relay and latches terminals #6 & #3.
NOTE: Terminal #5 is on the backside of the timer, glow plugs and indicator light will not be timed during starting
cycle.
3. The #6 terminal of the glow plug timer relay provides the ground source for terminal #86 of the glow plug
power relay. With current provided to terminal #85 and ground to terminal #86, the glow plug power relay
energizes latching terminals #30 and #87 of the relay. Terminal #87 provides current to the glow plugs,
allowing the glow plugs to generate heat to aid in starting the engine.
4. Terminal #87 also provides current to the glow plug lamp relay. This current energizes the relay. When the
relay is energized terminals 3-5 & 3-3 are latched completing the ground circuit for the glow plug indicator
light in the instrument panel, terminal #7, and with the #5 (7.5 amp fuse) supplying current to terminal #2 of
the instrument panel allows the indicator light to illuminate.
55-24

TROUBLESHOOTING

Starter motor will not energize Insufficient battery charge Test battery. Charge, add water, or
Defective 8-amp operator safety Inspect and replace circuit breaker

system circuit breaker as necessary

necessary

necessary
Defective PTO safety start or Test relays and replace as neces-

neutral start relay sary
Malfunctioning safety start switch Test neutral range, main PTO, mid
PTO (if equipped) and brake safety
start switches for adjustment,
proper operation, and faulty ground
circuits
Defective start circuit diode Test start circuit diode and replace
as necessary. Operator must be out
of seat for test.
Malfunctioning starter motor Test starter motor and repair or

Starter motor energizes, but fails to Defective operator safety module Test module and replace as
start engine (lacks exhaust smoke) necessary
Defective fuel shutoff relay Test fuel shutoff relay and replace
as necessary

Glow plugs will not energize Blown #1, 7.5 amp fuse Inspect and replace 7.5 amp fuse
as necessary
necessary
Defective glow plug timer or power Test relays and replace as
relay necessary
Corroded glow lug buss bar con- Check connection repair as needed
nection
Defective glow plugs Inspect and replace glow plugs as
necessary
Glow plug indicator light will not Blown #5, 7.5 amp fuse Inspect and replace 7.5 amp fuse
illuminate as necessary
Defective glow plug power or lamp Test relays and replace as
relay necessary
55-25
SAFE OPERATION CIRCUIT (OPERATOR PRESENT)
60043904
55-26
NOTE: The operating circuit is shown with:

• To the “B” terminal of the ignition switch
3. When the ignition switch is placed in the “ACC/RUN” position current is transferred across the following
ignition switch terminals:

2. The 8-amp circuit breaker supplies current to the operator safety seat switch and the fuel shutoff relay.
Seat switch and operator safety module

1. When the operator is in the seat, the seat switch closes and sends current to terminal “E” of the operator
safety module.
2. When current is present at terminal “E” of operator safety module, the ground path is completed by terminals
“B” and ”C” of module for the fuel shutoff relay.
Fuel shutoff relay

1. When current is provided to the fuel shutoff relay by the 8-amp circuit breaker and ground circuit is completed
by the operator safety module, the fuel shutoff relay is energized.
2. When the fuel shutoff relay is energized terminals 1-5 and 1-3 are latched providing current to the fuel shutoff
solenoid. When the solenoid is energized the solenoid plunger retracts and allows fuel to flow to the fuel
injection pump. This allows the engine to remain operating.
55-27

TROUBLESHOOTING

Engine does not continue to run Defective seat safety switch Test seat safety switch and replace
while operator is seated as necessary
Defective Fuel shutoff relay Test relay and replace as neces-

sary

Defective operator safety module Test module and replace as neces-

sary
Defective 8-amp operator safety Test circuit breaker and replace as

circuit breaker necessary
Open wiring in safe operation Check for loose connectors,

circuit grounds, and wiring damage
Engine continues to run after Defective seat safety switch Test seat safety switch and replace
operator has left seat for more than as necessary
two seconds and mid PTO and park
brake is not engaged
Defective operator safety module Test operator safety module and


Short-circuit in wiring or faulty Check for loose safety switch

ground circuit connectors, grounds, and wiring
harness for damage
55-28
PAGE LEFT BLANK
55-29
SAFE OPERATION CIRCUIT (OPERATOR NOT PRESENT)
60043905
55-30

• Transmission range lever in “NEUTRAL position
• Operator NOT in the seat
• Park Brake “ON”
• Mid PTO “OFF”

2. The 8-amp circuit breaker supplies current to the neutral start safety seat switch and the fuel shutoff relay.
Safety Switch Functions

1. With the range gear selector in neutral, the neutral start safety switch is closed and sends current to the mid
PTO switch.
2. The mid PTO switch is closed when the mid PTO is in the “OFF” position. If the tractor is not equipped with
a mid PTO the wiring harness will have a jumper harness installed to complete the circuit.
3. The mid PTO switch or jumper harness sends current to the park brake safety switch. With park brake “ON”
the park brake safety switch is closed and transfers current to the engine run with stationary rear PTO diode.
4. The diode sends current to terminal “E” of the operator safety module
5. When current is present at terminal “E” of operator safety module, the ground path is completed by terminals
“B” and ”C” of module for the fuel shutoff relay.
Fuel shutoff relay

1. When current is provided to the fuel shutoff relay by the 8-amp circuit breaker and ground circuit is completed
by the operator safety module, the fuel shutoff relay is energized.
2. When the fuel shutoff relay is energized terminals 1-5 and 1-3 are latched providing current to the fuel shutoff
solenoid. When the solenoid is energized the solenoid plunger retracts and allows fuel to flow to the fuel
injection pump. This allows the engine to remain operating.
Park Brake Indicator Light

Terminal #2 of the instrument panel is provided with current by the #5, 7.5 amp fuse and terminal #11, park brake
indicator light has the ground circuit completed by the park brake switch when the park brake is applied, allowing
the park brake indicator light to illuminate.
55-31

TROUBLESHOOTING

Engine does not continue to run Defective park brake safety switch Test seat safety switch and replace
while operator is not seated as necessary
Defective range neutral or fuel Test relays and replace as neces-

shutoff relay sary


sary
Defective 8-amp operator safety Test circuit breaker and replace as

circuit breaker necessary
Open wiring in safe operation Check for loose connectors,

circuit grounds, and wiring damage
Engine continues to run after Defective seat safety switch Test seat safety switch and replace
operator has left seat for more than as necessary
two seconds and mid PTO and park
brake is not engaged
Defective operator safety module Test operator safety module and

timer replace as necessary
Defective park brake or mid PTO (if Test switches and replace as
equipped) switch necessary
Defective range neutral or fuel Test relays and replace as neces-

shutoff relay sary


sary
Short-circuit in wiring or faulty Check for loose safety switch

ground circuit connectors, grounds, and wiring
harness for damage
Engine does not continue to run Defective range neutral switch, Mid Test components and replace as
when operator is not in seat, PTO switch, park brake switch, or necessary
transmission is in neutral, Mid PTO start circuit diode
is off, and park brake is engaged
55-32
PAGE LEFT BLANK
55-33
GLOW PLUG CIRCUIT
60043906
55-34
GLOW PLUG CIRCUIT

The engine glow plugs warm the engine pre-combustion chambers to assist in starting the engine in colder
temperatures.
The engine glow plug circuit is shown with :
• Ignition switch in the “ACC/RUN” position

• Glow plug indicator light illuminated
• Glow plugs activated
• Terminal # 30 of the glow plug power relay
travels through the #1, 7.5-amp fuse.
5. Current is supplied by the #1 fuse to terminal #85 of the glow plug power relay and terminal #4 of the glow
plug timer relay
Relay Functions
1. When the glow plug timer relay has current provided to terminal #4 and ground source to terminal #3, the
relay is activated, latching terminals #3 and #6.
2. Terminal #6 of the glow plug timer relay provides the ground source for terminal #86 of the glow plug power
relay. When ground source is provided to terminal #86 , the glow plug power relay is activated, latching
terminals #30 and #87.
3. Terminal #87 of the glow plug power relay provides current to the glow plugs until the glow plug timer relay
cuts of the ground source to the glow plug power relay.
4. Terminal #87 also supplies current to terminal 3-1 of the glow plug lamp relay.
5. The glow plug lamp relay has a ground source provide to terminals 3-2 and 3-5 by the tractor main ground.
6. With current provide to terminal 3-1 and ground to terminal 3-2 the glow plug lamp relay is activated , latching
terminals 3-3 and 3-5. Terminal 3-3 provides the need ground source for terminal #7 of the instrument panels
and the glow plug indicator light illuminates. Terminal #2 of the instrument panel provides the current from
the # 5, 7.5-amp fuse. The glow plug indicator light will illuminate until, the glow plug timer relay cuts off the
ground source to the glow plug power relay which provides current to the glow plug lamp relay.
55-35
ENGINE GLOW PLUG CIRCUIT

TROUBLESHOOTING

Engine glow plugs will not heat Insufficient battery charge Test battery. Charge, add water, or
Blown 40 amp main fuse Inspect main fuse and replace as

necessary
Blown #1, 7.5 amp glow plug circuit Inspect fuse and replace as
fuse necessary

necessary
Corroded electrode buss bar Remove buss bar, clean bar and
connection glow plug electrodes
Defective glow plug(s) Test glow plug(s) and replace as

necessary
Defective glow plug power relay Test relay and replace as neces-
sary
Glow plug indicator light will not Insufficient battery charge Test battery. Charge, add water, or
illuminate while key switch is in replace as necessary
“ACC/RUN/HEAT” or “START”
position Main fuse Inspect main fuse and replace as
necessary

necessary
sary
Faulty glow plug indicator bulb Check glow plug indicator light and
Defective glow plug indicator light Test timer and replace as neces-
timer sary
Glow plug indicator light circuit Check circuit connections,

open grounds, and wires
Defective glow plug lamp relay Test relay and replace as neces-
sary
Blown #5, 7.5-amp glow plug circuit Inspect and replace fuses as
or instrument panel fuse necessary
Glow plug indicator light remains Defective glow plug indicator light Test timer relay and replace as
illuminated after 5 seconds when timer relay necessary
keys switch is in “ACC/RUN”
position
Short circuit between the glow plug Check wiring between the instru-
indicator light and terminal “3--3” of ment panel and timer
the glow plug lamp relay.
55-36
PAGE LEFT BLANK
55-37
ROAD LIGHTS CIRCUIT
60046484
55-38
ROAD LIGHTS CIRCUIT

NOTE: The front lights are controlled by the rocker switch located on the dashboard. On gear model tractors the
lights are two 50 watt lights and on HST tractors the road lights are four 50 watt lights.
2. From the starter motor, current flows through the 40-amp fuse to a wire splice. The wire splice sends
current to:
• To the “B terminal of the ignition switch
travels through the #4, 15-amp fuse.
5. The #4, 15-amp fuse provides current to #2 terminal of the lights switch.
6. The #7, 20 amp fuse provides current to terminal #30 of the front lamp relay.
Switch Positions
• 1st position current is transferred from #2 to #3 Terminals, #3 terminal provides current to taillights and
instrument panel illumination
• 2nd position current is transferred from #2 to #3 terminals and #5 to #6 terminals for front head lights
• When current is provided to terminal #85 of the front lamp relay and a ground source is provided to terminal
#86, the relay latches, allowing current to transfer from terminal #30 to #87.
• Terminal #87 provides current to front headlights, two lights on gear models and four lights on HST models.
Ground Source
1. Ground source for front road lights is provide by main tractor ground, located at engine starter mounting bolt.
55-39
LIGHTING CIRCUIT
TROUBLESHOOTING

Front head lamps will not illuminate Insufficient battery charge Test battery. Charge, add water, or
or are dim replace as necessary
Head lamp bulb faulty Check and replace bulb as necessary
Blown 40-amp main fuse Inspect main fuse and replace as
necessary
Blown #4, 15-amp fuse Replace fuse as necessary.
Defective light switch Test light switch and replace as
necessary.
Improper connection at lamp termi- Check connections and lamp sock-
nals or headlight socket et. Repair or replace as necessary.
Improper ground connection Check ground connections and
repair as necessary.
Rear taillights will not illuminate or Insufficient battery charge Test battery. Charge, add water, or
are dim replace as necessary
Taillight bulb fault Check and replace bulb as necessary
necessary
necessary.
Improper connection at taillight Check connections and lamp sock-
lamp terminals or lamp socket et. Repair or replace as necessary.
Instrument panel illumination light Insufficient battery charge Test battery. Charge, add water, or
not illuminated or is dim replace as necessary
Instrument panel illumination bulb Check and replace bulb as necessary
burnt out
necessary.
Improper connection at instrument Check connections and socket.
panel terminals or light socket Repair or replace as necessary.
55-40
PAGE LEFT BLANK
55-41
HAZARD FLASHER CIRCUIT
60043909
55-42

current to:
• Fuse #6, 10-amp
3. The #6, 10-amp fuse provides current to :

• Terminal #3 of the hazard light switch
• Terminal 4-5 of the flasher cutoff relay
Hazard light switch

1. When the hazard light switch is placed in the “ON” position current is transferred from terminal #3 to terminal
#2 .
2. Terminal #2 of the hazard light switch provides current to:
• Terminal # 4-4 of flasher cutoff relay
• Terminal # 2 of the hazard/turn flasher module.
Flasher Cutoff Relay

1. Fuse #3 10-amp, provides current to terminal # 4-1 (coil side of relay) Ground source is provided to terminal
# 4-2 by tractor main ground located at the engine starter mounting bolt. This allows the relay to energize
and latch terminals # 4-3 and 4-5.
2. Terminal # 4-3 of the flasher cutoff relay provides current to terminal #1 of hazard/turn flasher module.
Hazard/Turn Flasher Module

1. With current provide to terminals # 1 and #2 of module and a ground source provided to terminal #6 the
module energizes. Allowing pulsating current to be sent out of terminals #3 and #4.
2. Terminal #3 of module sends pulsating current to hazard light switch internal bulb; left side rear hazard light
and left turn indicator light terminal # 9 of instrument panel. Allowing lights to flash on and off.
3. Terminal #4 of module sends pulsating current to right side rear hazard light and terminal # 19 of the
instrument panel. Allowing lights to flash on and off.
Ground Circuit
1. Ground source for rear hazard lights is provided by ground located at the left side of the HPL cover.
2. Ground for instrument panel terminal # 24 is provide by main ground, located at the engine starter mounting
bolt.
55-43

TROUBLESHOOTING

Hazard Signal Lights will not Blown #3, 10-amp hazard signal Inspect fuse and replace as neces-
illuminate or flash fuse sary
Blown #6, 10-amp fuse Inspect fuse and replace as neces-

sary
Hazard signal bulb(s) burnt out Inspect bulb(s) and replace as

necessary
Defective hazard switch Test switch and replace as neces-

sary
Defective flasher cutoff relay Test flasher relay by using a known

functioning flasher relay and re-
place as necessary
Defective hazard/turn flasher Test module and replace as neces-

module sary
Inspect the tractor’s wiring harness

Faulty wiring or ground connection and ground terminals for damage,
corrosion, and short circuits. Repair
or replace as needed
Instrument panel hazard indica- Indicator bulb(s) burnt out Inspect bulb and replace as neces-
tor(s) does not illuminate sary
Faulty wiring or ground connection Inspect the tractor’s wiring harness

and ground terminals for damage,
55-44
PAGE LEFT BLANK
55-45
RIGHT TURN SIGNAL CIRCUIT
60043910
55-46

NOTE: The right turn signal circuit is shown with the turn signal in the “Right” position.
to:
5. The #3,10-amp fuse provides current to terminal “A” of the turn signal switch.
Turn Signal switch /Flasher Module

1. When the turn signal switch is place in the “RIGHT TURN” position current is transferred from terminal “A”
to terminal “D” of the switch.
2. Current from terminal “D” of the turn signal switch is sent to terminal #7 of the hazard/turn flasher module.
3. When current is present at terminal #7 and ground source present to terminal #6 the flasher module is
energized. When energized the following terminal functions are:
• Terminal #3 left taillight continuous illumination
• Terminal #4 right taillight pulsating illumination
• Terminal #10 left hazard light continuous illumination
• Terminal #11 right hazard light pulsating illumination
Instrument Panel
1. Terminal #19 of the instrument panel is supplied pulsating current by terminal # 4 of the flasher module.
2. Terminal #9 of the instrument panel is supplied continuous current by terminal terminal #3 of the flasher
module.
3. Terminal #24 is the ground source for the instrument panel.
Ground Sources
1. Ground source for the flasher module and the instrument panel is the main tractor ground,. located at the
engine starter mounting bolt.
55-47

TROUBLESHOOTING

Directional signal will not illuminate Blown #3, 10-amp hazard or Inspect fuse and replace as neces-
or flash directional signal fuse sary
Directional signal bulb burnt out Inspect bulb and replace as neces-
sary
Defective hazard switch or direc- Test switches and replace as

tional signal switch necessary
Defective hazard/turn flasher mod- Test module and replace as neces-

ule sary

Instrument panel turn indicator Indicator bulb burnt out Inspect bulb and replace as neces-
does not illuminate sary

55-48
PAGE LEFT BLANK
55-49
LEFT TURN SIGNAL CIRCUIT
60043920
55-50

NOTE: The left turn signal circuit is shown with the turn signal in the “Left” position.
current to:
5. The #3,10-amp fuse provides current to terminal “B” of the turn signal switch.
Turn Signal switch /Flasher Module

1. When the turn signal switch is place in the “LEFT TURN” position current is transferred from terminal “B” to
terminal “C” of the switch.
2. Current from terminal “C” of the turn signal switch is sent to terminal #8 of the hazard/turn flasher module.
3. When current is present at terminal #8 and ground source present to terminal #6 the flasher module is
energized. When energized the following terminal functions are:
• Terminal #3 left taillight pulsating illumination
• Terminal #4 right taillight continuous illumination
• Terminal #10 left hazard light pulsating illumination
• Terminal #11 right hazard light continuous illumination
Instrument Panel
1. Terminal #9 of the instrument panel is supplied pulsating current by terminal terminal #3 of the flasher module.
2. Terminal #19 of the instrument panel is supplied continuous current by terminal # 4 of the flasher module.
3. Terminal #24 is the ground source for the instrument panel.
Ground Sources
1. Ground source for the flasher module and the instrument panel is the main tractor ground,. located at the
engine starter mounting bolt.
55-51

TROUBLESHOOTING

sary
Defective hazard switch or direc- Test switches and replace as

tional signal switch necessary

ule sary


55-52
PAGE LEFT BLANK
55-53
PTO INDICATOR LIGHT CIRCUIT
60043914
10
55-54


2. The 8-amp circuit breaker supplies current to the main PTO safety start switch.
PTO Safety Switch/ PTO Safety Start Relay

1. When the PTO is in the “ON” position, the PTO safety start switch is closed, sending current to terminal #
2-1 of the PTO safety start relay.
2. When current is provided at terminal # 2-1 and ground source provided to terminal # 2-2 the relay is
energized, latching terminals # 2-3 and # 2-5.
3. Terminal # 2-5 of the relay provides the ground source for terminal #12 of the instrument panel .
4. When a ground source is provide to terminal #12 and current is provide to terminal #2 of the instrument panel,
by the #5 7.5 amp fuse the PTO indicator light illuminates, warning the operator the PTO is in operation.
Ground Sources
1. Ground source for the PTO safety start relay is the main tractor ground, located at the engine starter mounting
bolt.
55-55

TROUBLESHOOTING

PTO light will not illuminate Blown, #5, 7.5-amp instrument Inspect and replace fuse as
panel fuse needed
Malfunctioning 8-amp operator Test circuit breaker and replace as

safety system circuit breaker necessary
PTO indicator bulb faulty Inspect bulb and replace as

necessary
Faulty wiring or ground terminal Inspect tractor wiring harness and

ground terminals for damage,
corrosion, loose connectors, or
short circuits. Repair or replace as
necessary.
Faulty main PTO switch Test switch and replace as

necessary
Faulty PTO safety start relay Test relay and replace as

necessary
Malfunctioning Instrument Panel Test instrument panel and replace

as necessary
PTO indicator light remains illumi- Main PTO switch improperly Check switch adjustment
nated adjusted
Defective PTO safety start relay Test relay and replace as neces-
sary

necessary.
55-56
PAGE LEFT BLANK
55-57
ENGINE COOLANT TEMPERATURE CIRCUIT
60043911
11
55-58


travels through the #5 7.5-amp fuse.
2. The #5 7.5-amp fuse supplies current to terminal #2 of the instrument panel.
Temperature Gauge
1. Two ground paths allow the engine coolant temperature gauge to function.
2. The first ground source is provide by terminal #24 of the instrument panel. This is a constant ground source
provided by the tractor main ground, located at the engine starter mounting bolt.
3. The needle within the temperature gauge is controlled by the second ground path. The second ground path
exists the gauge at terminal #15 of the instrument panel to travel to the engine coolant temperature sending
unit. At the sending unit, the resistance to ground changes as the engine temperature rises or lowers. The
temperature gauge translates this resistance into movement of the gauge needle. The greater the resistance
the less needle movement and the lesser the resistance the more the needle movement.

TROUBLESHOOTING

Inoperative temperature gauge Blown #5, 7.5-amp instrument Check 7.5-amp fuse and replace as
panel fuse necessary
Defective coolant temperature Test coolant temperature sending

sending unit unit and replace as necessary
Defective temperature gauge Test temperature gauge, replace

instrument panel as necessary
Faulty ground for temperature Check ground terminal at starter

gauge bolt. Repair as necessary
55-59
ENGINE LOW OIL PRESSURE INDICATOR LIGHT CIRCUIT
60043913
12
55-60

NOTE: The engine low oil pressure indicator light circuit shows the ignition switch in The “ACC/RUN” position
and the tractor engine in a low oil pressure condition.

Instrument Panel/Indicator Light

1. The instrument panel is provide with current to terminal #2 and the ground source for the indicator light is
provided by terminal #1. The ground path for the indicator light travels through the engine oil pressure switch
which is grounded directly to the engine cylinder head. When the engine oil pressure drops below 6 psi the
switch closes to complete the ground path to terminal #1 of the instrument panel. This allows the low oil
pressure indicator light to illuminate, warning the operator of a potential engine problem.

TROUBLESHOOTING

Oil pressure warning light remains Low engine oil pressure Test engine lubrication system and
illuminated repair as necessary
Defective oil pressure switch Test oil pressure switch and replace
as necessary
Oil pressure circuit is short- Check oil pressure switch, ground

circuited and wires for short circuit
Defective instrument panel Test instrument panel and replace

as necessary
Oil pressure warning light will not Blown #5, 7.5-amp instrument Replace fuse as necessary
illuminate panel fuse
Inspect warning bulb and replace
Faulty oil pressure warning bulb as necessary
Check oil pressure switch connec-

Oil pressure circuit open tions and wires
55-61
FUEL LEVEL CIRCUIT
60043912
13
55-62
FUEL LEVEL CIRCUIT


Fuel Gauge
1. Two ground paths allow the fuel gauge to function.
3. The needle within the fuel gauge is controlled by the second ground path. The second ground path exists
the gauge at terminal #14 of the instrument panel to travel to the fuel level unit. At the sending unit, the
resistance to ground changes as the fuel level rises or lowers. The fuel gauge translates this resistance into
movement of the gauge needle. The greater the resistance the less needle movement and the lesser the
resistance the more the needle movement.
FUEL LEVEL CIRCUIT

TROUBLESHOOTING

Inoperative fuel level gauge Blown #5, 7.5-amp instrument Check fuse and replace as neces-
panel fuse sary
Malfunctioning fuel level sending Test fuel level sending unit and
unit replace as necessary
Improper ground circuit Check fuel level sending unit

connections and circuit grounds
and repair as necessary
Malfunctioning fuel gauge Test fuel gauge and replace

55-63
PARK BRAKE INDICATOR LIGHT CIRCUIT
60043921
14
55-64

NOTE: The park brake indicator light circuit shows the ignition switch in the “ACC/RUN” position and the parking
brake applied.


provided by terminal #11. The ground path for the indicator light travels through the park brake switch which
is grounded by the chassis ground located at the left side of the HPL cover. When the park brake is applied
the switch closes to complete the ground path to terminal #11 of the instrument panel. This allows the park
brake light to illuminate warning the operator the park brake is applied.
PARK BRAKE INDICATOR LIGHT

TROUBLESHOOTING

Park brake indicator light will not Blown #5, 7-amp fuse Inspect and replace fuse as
illuminate needed.
Indicator bulb faulty Inspect bulb and replace as
necessary
corrosion, loose connectors or
short circuits. Repair or replace
as necessary
Faulty Park Brake switch Test switch replace as necessary
Park brake indicator light remains Faulty Park Brake switch Test switch replace as necessary
illuminated
as necessary
55-65
TACHOMETER CIRCUIT
60043922
15
55-66
TACHOMETER CIRCUIT

Alternator/Instrument Panel
1. Two supplied currents allow the tachometer to function.
2. First current is supplied to terminal #2 of the instrument panel by the #5 7.5-amp fuse
3. Terminal “T” of the alternator (HM61 coded wire) provides a signal current to terminal #20 of the instrument
panel. This current controls the tachometer’s RPM reading
4. The ground source is provide by terminal #24 of the instrument panel. This is a constant ground source
TACHOMETER CIRCUIT
TROUBLESHOOTING

Tachometer does not operate when Blown #5, 7.5-amp instrument Inspect and replace fuse as neces-
tractor engine is running panel fuse sary
Defective tachometer Test tachometer and replace instru-

ment panel as necessary
Tachometer pick-up wire damaged, Inspect tachometer pick-up, repair

corroded, disconnected or short- or replace as necessary
circuited
Faulty tachometer gauge ground Inspect and repair ground wire as

necessary
Defective alternator component Test alternator and components,

repair or replace as necessary
Inaccurate tachometer reading Malfunctioning tachometer Test tachometer and replace instru-
Loose alternator belt Adjust belt tension
55-67
AUXILIARY POWER SOCKET CIRCUIT
60043915
16
55-68

NOTE: The auxiliary power socket has current provided in any ignition key position. The power socket has a
10-amp maximum load rating.
current to:
• Fuse #6, 10-amp
3. Fuse #6 10-amp provides current to the power socket,

4. Ground source to the power socket is provided by the chassis ground, located at the left side of the HPL
housing.

TROUBLESHOOTING

Power socket does not have Blown #6, 10--amp fuse Inspect and replace fuse as
current present. needed.
Blown 40--amp main fuse Inspect and replace fuse as
needed.
as necessary
Corroded power socket Check socket for corrosion,
55-69
CRUISE CONTROL CIRCUIT (HST TRANSMISSION)
60043917
17
55-70

NOTE: The cruise control circuit is shown with the cruise control switch in the “SET” position and the brakes not
applied.
NOTE: The cruise control circuit can be activated with the HST linkage either in the forward or reverse position.

travels through the #5 7.5-amp fuse and the 8-amp circuit breaker.
2. The #5 7.5-amp fuse supplies current to terminal #8-3 of the cruise control relay.
3. The 8-amp circuit breaker provides current to terminal # 5 of the cruise control switch.
Cruise Control Switch

1. When the cruise control switch is placed in the “SET” position current is transferred from the #5 terminal to
the #6 terminal.
NOTE: The cruise control switch is a momentary type switch.
2. Current travels from the #6 terminal of the cruise control switch to terminal # 8-1 of the cruise control latch
relay also terminal #6 supplies terminal #8 of the switch for the internal light bulb of the switch.
Cruise Control Latch Relay

1. The ground circuit for the coil side of the relay is provided by terminal #8-2 of the relay. The ground circuit
is completed when the cruise control switch is placed in the “SET” position, this latches terminal #2 and #3
of the cruise switch. Terminal #3 of the cruise switch is provided with a ground source when the cruise brake
switch is in the closed position (brake not applied) connecting terminals “A” and “D” of the brake switch. The
ground source is proved by the chassis ground located on the left side of the HPL housing.
2. When terminal #8-1 is provide with current and terminal 8-2 is has a ground source, the relay is energized,
latching terminals #8-3 and #8-5 of the relay.
3. Terminal #8-5 of the relay provides current to:
• Cruise control diode
• Cruise control magnet
4. The Cruise control diode creates a “loop” circuit for the cruise relay, current is sent through the diode to
terminal # 8-1 of the relay, allowing the relay to stay energized and latched.
55-71
Cruise Control Magnet

1. When terminal “A” of the magnet is provide with current from terminal # 8-5 of the cruise relay and terminal
“B” of the magnet is provided with a ground source from the chassis ground. The magnet energizes and locks
the HST linkage in the desired location.
2. The magnet can be deactivated by either:
• Placing the cruise control switch in the “OFF” position
• Depressing the BOTH brake pedals
Either one of these actions will interrupt the current to the magnet causing the magnet to deactivate and release
the HST linkage.
NOTE: When the brake pedals are locked together the cruise control will deactivate. Depressing only the right
or left brake pedals will not affect the cruise circuit.
55-72

TROUBLESHOOTING

Cruise will not activate Blown #5, 7.5-amp fuse Inspect and replace the 7.5-amp
fuse as necessary
Defective 8-amp cruise control/op-
erator safety system circuit breaker Test and replace circuit breaker as
necessary
Defective cruise control switch
Test switch and replace as neces-
sary
Defective cruise control relay
Test cruise control relay and
replace as necessary.
Defective or stuck brake release
switch Test brake release switch. Replace
as necessary.
Cruise control activates, but does Defective cruise control switch Test cruise switch and replace as
not remain in “ON” position necessary.
Defective cruise control diode Test diode and replace as neces-

sary
Defective cruise control relay Test cruise control relay and

Cruise control magnet will not hold Cruise control magnet bracket is Adjust or tighten cruise control
hydrostatic transmission linkage in loose or improperly adjusted magnet as necessary.
position
Defective cruise control magnet Test cruise control magnet and
Excessive HST return spring pres- Reduce spring pressure

sure
55-73
HST RANGE “LOW” SHIFT CIRCUIT
60043918
18
55-74

Terminal “C” of Ignition Switch

2. The #5, 7.5-amp fuse supplies current to:
• Terminal # 6-3 High Range Shift Relay
• Terminal #2 of High /Low Range Shift Switch (Standard)
• Terminal #1 of High/Low Range shift Switch (Optional Switch loader control valve handle)
High/Low Switch (s)

1. When the range shift switch is placed in the “LOW” position, current flows out of terminal # 1 of the (standard)
or terminal # 4 of the (optional) switch. This current from the switch flows to terminal # 7-1 of the “LOW” shift
relay.
Low Shift Relay

1. When current is supplied to terminal #7-1 and a ground source to terminal # 7-2 (ground source provided
by main ground, located at engine starter mounting bolt.) The relay energizes, latching terminals #7-3 and
7-5 of the relay. This cuts off the ground circuit to the High shift relay.
2. When the Low shift relay is energized, the range shift solenoid does not receive current and is not activated.
This allows the hydrostatic motor to stay in “LOW” range.
3. When the High shift relay is not energized, terminals #6-3 and 6-4 are latched. Terminal #6-4 provides current
to terminal # 10 of the High/low Switch, terminal #9 of the switch is provided with a ground source and the
internal light bulb of the switch illuminates.
NOTE: “LOW” range is the default setting for the tractor hydrostatic system. When the tractor electrical system
is shutdown and reactivated the hydrostatic system will default to the “LOW” range.
55-75

TROUBLESHOOTING

Tractor will not switch into “LOW” Faulty range shift rocker switch Test and replace switch as neces-
range sary
Defective “HIGH” or “LO” shift relay Test relays and replace as neces-
sary
Defective range shift solenoid
Test solenoid and replace as
necessary
Fault in wiring or ground terminal
Inspect wiring harness and ground
terminal for damage, corrosion,
and short circuits. Repair or replace
as necessary.
Tractor will not switch out of “LOW” Blown #5, 7.5-amp shift control Inspect and replace the 7.5-amp
range fuse as necessary
Faulty range shift rocker switch
Test and replace switch as neces-
sary
Defective “HIGH” or “LO” shift relay
Test relays and replace as neces-
Defective range shift solenoid sary

Fault in wiring or ground terminal necessary

as necessary
“LOW” range bulb fails to illumi- Defective “LOW” range bulb Replace range shift switch
nate, but tractor shifts into “LOW”
range
55-76
PAGE LEFT BLANK
55-77
HST RANGE “HIGH” SHIFT CIRCUIT
60043919
19
55-78


High/Low Switch (s)

1. When the range shift switch is placed in the “HIGH” position, current flows out of terminal # 3 of the (standard)
or terminal # 5 of the (optional) switch. This current from the switch flows to terminal #2 of diode module,
through the diode module, to terminal #1 of module then to terminal # 6-1 of the high shift relay.
High Range Relay

1. When current is supplied to terminal #6-1 and a ground source to terminal # 6-2, the relay energizes, latching
terminals #6-3 and 6-5 of the relay. (Ground source provided through terminal #7-3 and 7-4 of the low shift
relay by main ground, located at engine starter mounting bolt.)
2. When the high shift relay is energized, terminals #6-3 and 6-5 latch.
3. Terminal # 6-5 supplies current into two different paths:
• One path sends current to the range shift solenoid, the solenoid is grounded by the chassis ground, which
is located on the left side of the HPL housing. This allows the solenoid to energize and shift the hydrostatic
motor into “HIGH” range.
• The other path flows to terminal #4 of the diode module through the diode module and exists out terminal
#3. From terminal #3 current travels to terminal #1 of diode module, the diode blocks current to terminal
#2 of module. This diode forces current to travel to terminal #6-1 of high shift relay, this current allows
the relay to remain energized and keep the hydrostatic transmission in “HIGH” range.
• Terminal #4 of the diode module also supplies current to terminal #8 of the High/Low switch. Terminal
#7 of the switch is supplied with a ground source provide by the chassis ground located on the left side
of the HPL housing. This allows the internal bulb in the switch to illuminate.
55-79

TROUBLESHOOTING

Tractor will not switch into “HIGH” Blown #5, 7.5-amp shift control Inspect and replace fuse as neces-
range sary
Faulty range shift rocker switch Test and replace switch as necessary
Defective “HIGH” or “LO” shift relay Test relays and replace as necessary
Defective range shift solenoid Test solenoid and replace as

necessary
Defective range shift diode(s) Test diode(s) and replace as

necessary
Fault in wiring or ground terminal Inspect wiring harness and ground

as necessary
Low charge pressure Check HST charge pressure relief

valve
Tractor will not switch out of “HIGH” Faulty range shift rocker switch Test and replace switch as necessary
range

necessary

as necessary
“HIGH” range bulb fails to illumi- Defective “HIGH” range bulb Replace range shift switch
nate, but tractor shifts into “HIGH”
range
55-80
PAGE LEFT BLANK
55-81
CHARGING CIRCUIT
60043916
20
55-82
CHARGING CIRCUIT
NOTE: The charging circuit is shown with the ignition switch in the “ACC/RUN” position and the engine running.
2. From the starter motor, current is split into two paths:
• “B” terminal of the alternator
• 40 amp main fuse
3. Current flows through the 40-amp fuse to a wire splice. The wire splice sends current into two directions:

travels through the #5 7.5-amp fuse and #1, 7.5-amp fuse.
3. The #1 7.5-amp fuse provides current to the “R” terminal of the alternator.
Alternator/Indicator Light
1. If the tractor engine is not running or the alternator is not producing a sufficient amount of charge, (with key
switch in the “ACC/RUN” position) the charge light will illuminate.
• The current for the indicator light is provided by terminal #2 of the instrument panel.
• The ground source for the indicator light is provided by terminal #6 of the instrument panel. From terminal
#6 the ground path passes through a diode which is an internal part of the instrument panel circuitry, then
to the “L” terminal of the alternator. The ground source for the “L” terminal is provided by the alternator
field coil.
• When the ground circuit is complete to terminal #6 and current is provided to terminal #2 by the #5,
7.5-amp fuse, the charge indicator light will illuminate.
2. When the tractor engine is running with the alternator rotating and the ignition switch in the “ACC/RUN”
position, the alternator produces an increased regulated voltage to the battery.
• When the alternator is producing current, the ground circuit, through the “L” terminal, for the charge
indicator light is disrupted, causing the indicator light to not illuminate.
• The “R” regulator terminal controls the voltage output from the alternator. If current is not present at the
“R” terminal the alternator will not produce current.
• The “B” terminal of the alternator is the output connection between the alternator and the battery.
55-83
CHARGING SYSTEM CIRCUIT

TROUBLESHOOTING

Charge light remains illuminated Faulty alternator component Test alternator and repair a neces-
sary
Short circuit to ground between Check wiring and repair as neces-

alternator and warning lamp sary
Charge light does not illuminate Blown #5, 7.5-amp instrument Inspect 7.5-amp fuse and replace
panel fuse as necessary
Faulty charge indicator bulb Inspect indicator bulb and replace

as necessary
Open charge light circuit Inspect connections, grounds, and

wiring for charge circuit and repair
as necessary
Insufficient or no battery charge, Battery charge less than 75% Test battery. Charge, add water, or
hard starting, or dim indicator light replace as necessary
Fan belt slipping Check fan belt tension, adjust as

necessary
Loose wiring connections Check wiring connections for

charge circuit, repair as necessary
Continuity fault in external wiring Check wiring harness and repair as

necessary
Blown #1, 7.5-amp alternator Inspect 7.5-amp fuse and replace

excitation fuse as necessary
Battery failure, frequent burnout of Overcharge condition Check alternator voltage output
lamps and fuses and repair as necessary
Ground circuit for alternator short- Check alternator wiring and con-
circuited nections and repair as necessary
55-84
Chapter 3 - Instrument Panel
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instrument Panel Indicator and Illumination Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bulb Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
55-1
COMPONENT OPERATION AND SERVICING
INSTRUMENT PANEL
The following components of the instrument panel
are serviced separately:
1. Lens
2. Bezel
3. Rear Cover
4. Fuel Gauge
5. Tachometer
6. Temperature Gauge
7. Indicator/Illumination Bulbs
NOTE: The hour meter is not serviced as a separate
component. Replace the Instrument Panel assembly
if there is a performance problem with the hour meter.
3 5
6
4
7
2
50043884
55-2
6 12
5 7
1 10
11 8 8 11
2 4 3 9
50035983
2
1. Cold Starting Indicator Light -- Illuminates 7. Temperature Gauge -- Indicates coolant tem-
when the key switch is turned to the “ACC/RUN” perature. It is activated when the key switch is
position. It remains lit for approximately four turned to the “ACC/RUN” position. The gauge will
seconds when the key is in position, during which register “cold” with the key switch in the “STOP”
time the glow plugs are heating the precombus- position. If the needle registers in the green
tion chambers of the cylinder head. range of the gauge, this indicates a normal
operating temperature. If the needle moves to
2. Engine Oil Pressure Warning Light --
the red portion of the gauge, indicating an
Illuminates with the key switch in the “ACC/RUN”
overheated condition, stop the tractor engine
position and remains lit for a short period of time
IMMEDIATELY and investigate the cause.
after the engine is started. The light indicates oil
pressure only, and goes out when sufficient oil 8. Flasher Warning Hazard Lights -- Operate
pressure is present at the oil sender. If the bulb when the flasher switch is turned on, regardless
lights during operation, stop the tractor engine of the key switch position. Use the flasher
immediately and investigate the cause. warning lights and the SMV placard when
traveling on public roads, day or night.
3. Battery Charge Warning Light -- Illuminates
when the key switch is in the “ACC/RUN” position 9. Parking Brake Light -- Illuminates if the parking
and goes out when the engine is started. If this brake is engaged when the key switch is turned
bulb lights during operation, it indicates that the from the “OFF” position.
charging system is not operating normally. As the
10. PTO “On” Indicator -- When the rear PTO
battery can become fully discharged under these
position is engaged, and the key switch is in the
conditions, the problem should be investigated
“ACC/RUN” or “START” position, this indicator
as soon as possible.
will be illuminated amber.
4. Proof Meter -- Records the hours and portions of
11. Flasher Turn Lights -- Operate when the turn
hours that your tractor has been operated,
signal switch is moved forward for right turns (the
regardless of engine RPM. Use the proof meter
RH arrow will flash) or rearward for left turns (the
as a guide to determine hourly service and
LH arrow will flash.) The key switch must be in the
maintenance intervals.
“ACC/RUN” or “START” position for the turn
5. Fuel Gauge -- Indicates the amount of diesel fuel signals to operate.
remaining in the tank. The gauge is activated
12. PTO Speed Indicator -- Determined by the
when the key switch is in the “ACC/RUN”
position of the needle on the tachometer. The
position. It will resister “empty” with the key
tachometer is marked to indicate 540 PTO RPM.
switch in the “STOP” position.
If the needle registers above the 540 RPM mark,
6. Tachometer -- Registers engine RPM (Revolu- this indicates a dangerous over speed condition,
tions Per Minute) The gauge is marked in and the engine RPM should be reduced
increments of 100 and will return to zero when immediately. (only on HST tractor)
the engine is not running.
55-3
Removal
Remove the two screws, 1, from each side of the 1 1
instrument panel and pull the panel assembly out of
the dash.
NOTE: Additional wire harness length is provided so

that the instrument panel can be removed from the
mounting without unplugging the harness.
50035983
COMPONENT TESTING AND REPLACEMENT

FUEL GAUGE
Testing
Instrument panel viewed from rear, pin #s are not
marked on panel
1. Remove the two retaining screws, 2, from panel
and remove rear cover to expose circuit board. 2
50043883
4
2. Using an ohmmeter, measure the resistance
between pins: 3
#1 and #2 = The measured resistance should be
between 223 and 301 ohms.

between 78 and 106 ohms

If the resistance measure is outside the ranges or a 2 1

open circuit is measured, the fuel gauge should be 50043882
replaced.
5
55-4
Replacement
1
1. Remove the ten retaining screws, 1, from the rear
of the panel, then remove the lens and bezel from
the panel body.
50043883
6
2. Remove the gauge face plate retaining screw, 2
from the panel.
2
50043881
7
3. Remove the three retaining nuts, 3, from the
circuit board and remove the fuel gauge from the 3
front on the instrument panel.
4. Insert new fuel gauge into panel, secure with face
plate retaining screw and nuts. Reassembly lens
and rear cover.
3
50043882
55-5
TEMPERATURE GAUGE
Testing
Instrument panel viewed from the rear, pin #s are not
marked on panel
1. Remove the two retaining screws from panel, 1,
50043883
9
between pins:
3


between 223 and 301 ohms 2
1
If the resistance measure is outside the ranges or a 50043882
open circuit is measured, the temperature gauge
should be replaced. 10
Replacement
2
the panel body.
50043883
11
55-6
from the panel.
3
50043881
12
circuit board and remove the temperature gauge 4
from the front on the instrument panel.
4. Insert new temperature gauge into panel, secure
with face plate retaining screw and nuts.
Reassembly lens and rear cover.
4
50043882
13
TACHOMETER
Testing
marked on panel
50043883
14
55-7
between pins: 4 1

If the resistance measure is outside the ranges or a

open circuit is measured, the tachometer should be
replaced.
3 2
50043882
15
Replacement
2
the panel body.
50043883
16
55-8
2. Remove the tachometer face plate retaining
screws, 3 from the panel. 3
50043881
17
3. Remove the four retaining nuts, 4, from the circuit
board and remove the tachometer from the front 4
on the instrument panel.
4. Insert new tachometer into panel, secure with
face plate retaining screws and nuts. Reassemb-
ly lens and rear cover.
50043882 4
18
55-9
INSTRUMENT PANEL INDICATOR AND

ILLUMINATION LIGHTS
Bulb Identification Chart
BULB # DESIGNATION CANDLE POWER

1 ILLUM - TEMP GAUGE 0.7
2 ILLUM – TACHOMETER 0.7
4 ILLUM – FUEL GAUGE 0.7
5 WARN – PTO 0.7
6 WARN – PARK BRAKE 0.7
7 WARN – HEAD LIGHT 0.7
8 HAZARD LIGHT 0.7
9 RIGHT TURN SIGNAL 0.7
10 LEFT TURN SIGNAL 0.7
11 WARN – BATT. CHARGE 0.7
12 WARN – OIL PRESSURE 0.7
13 WARN – PREHEAT 0.7
14 ILLUM – HOUR METER 0.7
3
2
1 4
10
5 7 9 11 12 13
6 8 14
50043882
19
55-10
Bulb Replacement
1. Remove the two retaining screws, 1,from panel 1
and remove rear cover to expose circuit board.
2. Rotate bulb assembly counterclockwise a
quarter turn and remove bulb assembly from the
instrument panel.
3. Insert bulb assembly into appropriate hole in
circuit board, turn bulb assembly a quarter turn
clockwise
4. Reassemble rear cover to instrument panel.
50043883
NOTE: All bulbs are the same candle power (0.7) and
are interchangeable in positions. Part #87300474 20
55-11
Instrument Panel Master Plug Identification -- As viewed from rear of instrument panel
50043883
21
1 5 9 13 17 21
2 6 10 14 18 22
3 7 11 15 19 23
4 8 12 16 20 24
Pin # Function Pin # Function
1. Engine Oil Pressure Indicator Light 13. Open

2. Switched Power (+) 14. Fuel Level Gauge
3. Open 15. Engine Temperature Gauge
4. Open 16. Open
5. Open 17. Trailer
6. Alternator Charging (--) 18. (High Beam)
7. Glow Plug Indicator Light 19. Right Turn Signal Indicator Light
8. Open 20. Engine RPM
9. Left Turn Signal Indicator Light 21. Open
10. Open 22. Open
11. Parking Brake Indicator Light 23. Panel Illumination
12. PTO Indicator Light 24. Constant Ground (--)
55-12
Chapter 4 - Alternator and Starter
CONTENTS

Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
55-1

Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
55-2
ALTERNATOR SPECIFICATIONS
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mitsubishi
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A007T03877
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative Ground
Rotational Direction (viewed from pulley) . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 15 mm (0.39 – 0.59 in.) deflection

@ 9 – 11 kg. (20 – 25 lb.) of force
Adjusting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 – 15.0 volts
Load Characteristics
Terminal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 volts
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 amp minimum
Rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500
Brush Length
Wear Limit (min. length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.20 in.)
Original . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 mm (0.728 in.)
Brush Contact Rings

Wear Limit (min. diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1 mm (0.871 in.)
Original Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7mm (0.894 in.)
Bearing
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECSC8
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6303DDG
Stator Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . less than 1.0 ohm
Rotor Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 ohms
55-3
ALTERNATOR TROUBLESHOOTING
NO CHARGING
FAULT LOCATION POSSIBLE CAUSE CORRECTION
Wiring Loose connection, short circuit Repair
Alternator Loose connection, no ground, short Repair or replace
circuit
Defective rectifier Replace
Loose connection on RF resistor Replace
Regulator Defective regulator Replace
Loose connection of alternator or Repair or replace
regulator
INSUFFICIENT CHARGING
Wiring Loose connection or short circuit Repair
Alternator Loose drive belt Repair
Short in rotor coil Replace
Short in stator coil Replace
Insufficient brush contact Repair or replace
Loose connection of alternator and Repair
regulator
Battery Defective battery Replace
OVERCHARGE
Battery Internal short Replace
55-4
UNSTABLE CHARGING CIRCUIT

Wiring Loose connection or open wire Repair or replace
Broken brush or spring Replace
Loose connection Repair
Loose connection at alternator and Repair or replace
regulator
ABNORMAL NOISE OF ALTERNATOR

Alternator Loose mounting hardware Repair
Defective bearings Repair or replace
Rotor core and stator in contact Replace
Defective diode Replace
55-5
CHARGING SYSTEM
2 7
1
5
6
1
Op. 55 301
ALTERNATOR
Description of Operation The IC regulator, 4, is a solid state unit and can only
Tractors are equipped with a 40-amp output be serviced as an assembly.
alternator. The alternator is equipped with an
integrated circuit (IC) regulator, meaning voltage is The internal components of the alternator are
regulated internally and electronically within the housed in a two-piece frame, which is divided into a
alternator. drive end (front) frame, 5, and a rear frame, 6. The
frame contains open slots to allow for cooling of the
The principle components of the alternator are the alternator.
stator, 1, the rotor, 2, the rectifier assembly, 3, and the
IC regulator, 4. The alternator is rotated in the frame by using a
belt-driven pulley, 7, which is powered off of the
The rectifier assembly, 3, consist of two heat sinks, engine crankshaft pulley by a belt
one positive (+) and one negative (--), and a diode
trio. The diode trio is use as a field supply diode and
is connected to terminal “L” on the alternator.
55-6
B
P
4 6
L
3
R
L R
D6
R
R6 R5 L
F R1
Dz 7
Tr2 Tr1 R2
2
E
2
Charging Circuit Principle of IC Regulator
The charging circuit and internal connections are The basic function of the IC voltage regulator is to
shown. The charging system consists of an IC make the terminal voltage constant by detecting the
voltage regulator, 1, (enclosed with dotted lines), a generated voltage and increasing/decreasing the
battery, 7, and connecting wires. Because of the use field current.
of IC, the voltage regulator is very compact and is
built into the alternator. As indicated, the regulator consists of two basic
sections: a voltage control device and an output
The IC voltage regulator, 1, permits the field current device to handle the field current. The voltage control
to flow directly from the diode trio, 4, to the field coil, device includes the voltage divider network, R1 and
2, without passing through the external circuit. R2, a zener diode, DZ, for voltage reference, and a
Consequently, there are no voltage drops caused by single amplifying transistor, Tr1. The output device is
the key switch or the external wiring as with a darlington-type amplifier which is called power
conventional vibrating-contact regulators mounted transistor, Tr2. The power transistor, Tr2, is placed in
separately from the alternator. To aid in initial voltage series with the alternator field coil and ground.
buildup when the engine is started, the field current
is supplied through the indicator lamp, 5, from the The signal amplifying transistor, Tr1, senses the
battery, 7. generated voltage and turns the power transistor,
Tr2, on and off many times per second most of the
Since the frequency pulse output of 1/10 the time the engine is in operation.
alternator speed develops on the “P” terminal, this
terminal is used for speed detection.
55-7
The basic operating principles are explained as 5. As the speed and voltage increase, the voltage
follows, see Figure 2: at point “A” also increases until it reaches the
limiting value set at the factory. As the zener
1. When the key switch, 6, is closed, current from diode, DZ, breaks down, current flows through
the battery, 7, flows through the indicator lamp, 5, R1, DZ, and the base-emitter circuit of Tr1 to
and resistor R6, which are in parallel to the field ground. This renders Tr1 conductive, so that
coil, 2. From here it continues to flow on through much of the current flows through the collector-
the field coil, 2, to the ground, completing the emitter circuit of Tr1. This reduces the base
circuit back to the battery, 7. current of Tr2 thereby reducing the field current.
This means that Tr1 turns on and Tr2 turns off.
2. When the alternator begins to rotate, AC
voltages are generated by the stator coil, 3. The 6. When the generated voltage decreases, the
diodes in the rectifier assembly change the stator zener diode, DZ, again turns off and Tr1 also
AC voltages to DC voltage which appears turns off. This cycle repeats many times per
between ground and the “B” terminal. second, and the alternator output voltage is,
therefore, regulated within a narrow limit.
3. The stator also supplies DC field current through
the diode trio, 4, the field coil, 2, the power In other words, the action is similar to the
transistor, Tr2, and then through the diodes in the conventional vibrating-contact regulator, in that
rectifier assembly back to the stator. current to the field coil, 2, is varied to limit the
output voltage, but in place of the voltage coil and
4. When the generated voltage is low, no current spring system, there is a voltage divider network,
flows in the zener diode, DZ, since the voltage at R1 and R2, and a zener diode, DZ.
point “A” is lower than the zener voltage.
55-8
PRELIMINARY ALTERNATOR TESTS

Alternator Drive Belt
1. Check the alternator drive belt deflection by
applying 9-11 kg. (20-25lb.) of force between the
crank pulley and the alternator pulley, 1. Belt
deflection should be 10-15mm (0.39-0.59in.).
3
1. If the drive-belt deflection needs adjusted,
loosen the adjusting/mounting bolts, 1, and 1
adjust the alternator as needed to obtain proper
belt deflection.
4
Alternator Output
NOTE: Use the following methods if an alternator/ KEY
charging system analyzer is unavailable. SWITCH
VOLT 1 L
METER
1. Connect a 50-amp capacity test ammeter R
between the positive (+) battery cable and the ALTERNATOR AMMETER
key switch.
2. Connect a voltmeter to the battery terminal, 1, of
the alternator and to a ground source. BATTERY
3. Observe the voltmeter. The meter should
indicate battery voltage. If the voltmeter does not
read battery voltage, the wiring between the
alternator and the battery may be faulty and
5
should be repaired or replaced.
WARNING
Do not attempt to start the engine without first
shorting the wires between the ammeter leads.
Otherwise, injury or damage to the charging and
testing components may occur.
4. Use a jumper wire to short the test ammeter

leads and start the tractor engine.
55-9
5. After the tractor engine is started, remove the voltage that what is indicated when voltage is
jumper wire between the test leads of the taken at the battery. If the reading is not higher,
ammeter. the alternator is not generating enough voltage
and a component may be malfunctioning.
6. Increase the engine speed to approximately
2000RPMs and observe the ammeter reading. 8. If the ammeter indicated more than 5 amps,
continue to charge the battery until the ammeter
7. If the ammeter indicates 5 amps or less, observe
reading falls below 5 amps. If the reading does
the voltmeter reading. The voltmeter is indicating
not fall below 5 amps, test the battery or replace
adjusting voltage, which is the amount of
the battery with one that is fully charged.
increased voltage the alternator supplies to the
battery. The reading should indicate a higher
20000898
NOTE: bench testing the alternator will achieve the 3. Apply the parking brake and start the tractor
best results for the following tests. (see alternator engine. Turn on all 12-volt powered accessories
bench testing). such as headlight and indicator lights. Immedi-
ately raise engine RPMs to 2000 or more to
1. If the previous test was satisfactory, open the key record the maximum value indicated on the
switch (OFF) and connect an ammeter between ammeter.
the battery terminal “B”, of the alternator and the 4. If the amperage value is more than 70% of the
battery wire, as shown. nominal alternator output, as described in
2. Connect the positive (+) lead of a voltmeter to the alternator specifications, the alternator is consid-
“B” terminal on the alternator. Connect the ered to be working satisfactorily.
negative (--) lead to a suitable ground. Confirm
that the voltmeter indicated battery voltage.
55-10
Alternator Removal
the negative battery terminal.
6. Disconnect all wiring, 1, from the rear of the 1
alternator.
7. Loosen the alternator mounting bolts, 2, and
remove the V-belt, 3, from the alternator drive
pulley. 2
8. Remove the alternator mounting bolts, 2, and
remove the alternator from the tractor engine.
3
1 8 9
5 15
4
13
3
14
7
6
12 11
2
10
20000901
8
1. Alternator Assembly Alternator Disassembly
2. Pulley Nut 1. Mark the front alternator frame, 5, the rear
3. Pulley Assembly alternator frame, 11, and the stator, 10, with
4. Bolt scribe marks to insure that the alternator is
5. Front Alternator Frame Assembly assembled as taken apart.
6. Bolt
7. Front Rotor Bearing
8. Rotor Assembly
9. Rear Rotor Bearing
10. Stator
11. Rear Alternator Frame Assembly
12. Terminal Assembly
13. IC Regulator Assembly
14. Rotor Brush and Spring
15. Rectifier
55-11
2. Remove the four (4) alternator frame retaining

bolts, 1. 3
2
3. Carefully separate the front frame, 3, and the rear 4
frame and stator, 2. The rotor assembly, 5, and
the pulley, 4, will be removed with the front frame, 1
3.
9
4. To remove the pulley nut, 1, use an impact
wrench or place the rotor, 6, into a soft jaw vice
and use a wrench. Remove the washer, 2, the
pulley, 3, spacer, 4, and the front frame, 5, from
the rotor, 6.
1
6
5
2 3 4
10
NOTE: When removing the rear rotor bearing from
the rotor, be sure to apply even pressure to the rear 1
rotor bearing. 3
5. The rear rotor bearing, 2, may be removed from

the rotor, 1, by using a bearing puller, 3.
11
55-12
6. Remove the three (3) screws, 1, which secure

the regulator/ rectifier assembly, 2, to the rear 1
alternator frame.
2
10002261
12
7. Remove the battery terminal nut, 1, from the rear
of the alternator frame. 1
8. Carefully remove the stator and the regulator/
rectifier assembly from the rear alternator frame.
20002269
13
CAUTION
2 1 3
Preheat the soldering iron before attempting to
unsolder the stator leads or the regulator/rectifi-
er assembly. To avoid any damage to the rectifier
diodes, use a pair of needle-nose pliers to
remove the excess heat from the area being
soldered. Hold the pliers just below the solder
joint on the rectifier to remove excess heat. Use
a damp cloth to cool the components once they
have been separated.
9. Unsolder the three stator leads, 1, and remove 10002262

the stator, 2, from the rectifier/regulator assem-
bly, 3. 14
55-13
10. Unsolder the IC regulator assembly, 1, from the
rectifier assembly, 2, at the solder joints, 3. 1
2
10002263
15
11. Remove the four (4) screws, 1, from the front
alternator frame, 4. Remove the retaining plate, 3
2, and the front rotor bearing, 3. 4
16
55-14
ALTERNATOR COMPONENT TESTING AND

INSPECTION
Stator
1. Using an ohmmeter, touch the ohmmeter test
probes to different leads of the stator coil.
read a resistance of less than 1 ohm, for each of
the phase wires, indicating continuity.
3. If there is no continuity, inspect the lead wire
connection for breaks. The lead wire may be
repaired with solder if damage is not excessive.
If the lead wire is good, the stator coil is faulty and
needs replaced.
17
4. Using an ohmmeter, touch one of the ohmmeter
test probes to the stator coil and the other test
probe to the stator core.
5. Observe the ohmmeter. Resistance should be
high, indicating no continuity between the coil
and the core. If there is continuity, the stator is
18
55-15
Rotor
1. Inspect the rotor brush contacts, 1, for pitting,
roughness, and dirt. If necessary, use # 600 grit
fine sandpaper to clean dirt off of the contacts. If
the contacts are pitted or damaged excessively,
replace the rotor.
SM463-173
19
2. Use a suitable measuring device to determine
the outer diameter of each brush contact. The
minimum outer diameter of the brush contacts is
22.1 mm (0.871 in.).
20
3. Using an ohmmeter, touch one ohmmeter test
probe to a brush contact. Touch the other test
probe to the remaining brush contact.
4. Observe the ohmmeter. The ohmmeter resist-
ance reading should be approximately 3 ohms.
If the reading is not as specified, the rotor is
21
55-16
NOTE: When testing the resistance between the

brush contacts and rotor poles, be sure that the 1
ohmmeter test probe touching the rotor pole is not
insulated by paint.

probe to one of the rotor brush contacts, 1, and
the other test probe to one of the rotor poles, 2.
high, indicating no continuity between the rotor
poles and brush contacts. If there is continuity, 2
the rotor is defective and needs replaced.
22
Rectifier Assembly
1. Using an ohmmeter, touch the positive (+) test
probe to the positive (+) portion of the diode
plate, 1, and the negative (−) test probe to the
other test probe to a stator coil lead connection
terminals, 2.
2. Observe the ohmmeter for continuity.
3. Now switch the positions of the test probes and
observe the ohmmeter for continuity. The
1 2
ohmmeter should indicate continuity in one
direction only. If there is continuity in both
directions or no continuity at all, the rectifier
assembly is defective and needs replaced.
23
4. Using the same procedure described in the three
previous steps, test the diodes between the
negative (--) portion of the diode plate, 1, and the 1
stator lead connections, 2. Again, replace the
rectifier assembly if the diodes test defective.
24
55-17
5. Test each of the three small diodes, 1, by
touching the positive (+) ohmmeter test probe to 1
one end of a diode and the negative (−) test probe
to the opposite end of the diode.
directions, or no continuity at all, the rectifier
25
Alternator Brushes
1. Carefully clean the alternator brushes with a soft,
dry cloth and electrical component cleaner, if
available.
2. Inspect the brushes and brush springs for
corrosion, damage, stretched springs, or a 0.728″ 0.20″ (5mm)
damaged brush holder. If damaged, replace the (18.5mm)
brush assembly.
3. Use a suitable measuring device to measure WEAR LIMIT
brush wear. The minimum brush length is 5 mm NEW USED
(.020 in.). If either brush is worn beyond BRUSH BRUSH
specifications, replace the brush assemblies.
26
Alternator Bearings
1. Inspect the alternator bearings for smooth
operation by spinning the bearing. Replace 2
bearings that are rough and do not rotate 3
smoothly. 1
2. Inspect the bearings for grease leakage between
the bearing seal, 3, and races, 1, and 2.
3. Inspect the inner race, 1, and the outer race, 2,
for signs of spinning in the alternator frame or on
the rotor shaft.
4. Replace bearings that are damaged in any way.
27
55-18
Drive Pulley
1. Inspect the drive pulley for a worn, bent, cracked,
1
or otherwise damaged belt groove, 1.
2. A polished surface in the bottom of the belt
groove indicates a worn pulley.
28
Alternator Frames
2
1. Inspect the bearing housing bores, 1, for scoring,
cracks or evidence that the bearing was spinning
inside the bore.
2. Inspect the frames for cracked or broken
mounting bosses, 2, or any other distortion or
damage.
1
1
2
2
29
Assembly
NOTE: When installing the rear rotor bearing, be
sure that top sleeve used to press the bearing onto
the rotor contacts the inner race of the bearing only. 2
1
1. Install the rear rotor bearing, 1, and spacer onto
the rotor by using a press, 2, and two sleeves,
such as tubing or 15-mm deep sockets, 3. The
bottom sleeve will support the rotor as the top
sleeve presses the rear bearing spacer onto the
rotor.
30
55-19
2. Install the front rotor bearing, 3, and front bearing
retaining plate, 1, into the front alternator frame, 4, 1
and secure using the four (4) retaining screws, 2.
31
3. Install the washer, 2, pulley, 3, spacer, 4, and
front frame, 5, onto the rotor, 6.
4. To install the pulley nut, 1, use an impact wrench
or place the rotor, 6, into a soft jaw vice and use
a wrench to tighten the pulley assembly to the
rotor. 1
6
5
2 3 4
32
55-20
5. Use the following guidelines when soldering

alternator components.
• Clean all terminals to be soldered and
remove excess solder.
• Preheat the soldering iron and use rosin-core
solder to solder terminals and/or wires. To
avoid damage to the rectifier diodes, use a
pair of needle nose pliers to remove excess
heat from the area being soldered. Hold the
pliers just below the solder joint on the
rectifier to remove excess heat.
• Make good, solid, solder joints for best
alternator performance.
• After soldering, quickly cool the solder joint 33
with a damp cloth.
6. Solder the IC regulator, 1, and rectifier, 2,
together. 1 2
10002263
34
7. Solder the stator leads, 1, to the terminals on the
rectifier/regulator assembly, 2. 1 3
10002262
35
55-21
NOTE: Secure the regulator/rectifier assembly to the
rear alternator frame before pressing the stator into 1
the rear frame.
2
8. Secure the regulator/rectifier assembly, 2, to the
rear alternator frame using the three (3) retaining
screws, 1. Manually press the stator assembly
into the rear alternator frame.
10002261
36
9. Install the battery terminal nut, 1, to the rear of the
alternator frame. 1
20002269
37
10. Push the brushes, 1, and springs, 3, into the
brush holder and insert a piece of wire, 2, through
the rear of the alternator frame and into the brush
3
holder to hold the brushes out of the way while
the alternator halves are being assembled.
1
38
55-22
11. Assemble the front alternator frame, 3, and rear

alternator frame, 2, together. Be sure to align the 2 3
scribe marks made when the alternator was
disassembled to insure proper reassembly. Use
the four (4) bolts, 1, to secure the front and rear 1
frames together.
39
Alternator Bench Check
1. Connect the alternator to a testing circuit, as
shown. Set the load resistance to zero (0).
AMMETER SWITCH
NOTE: Alternator rotation direction is clockwise, as A
viewed looking at the pulley.
VOLT- B
L
METER V
2. Slowly increase the alternator rotational speed R LOAD
BATTERY
and observe the voltage reading indicated on the RESISTOR
ALTERNATOR
voltmeter.
3. If the voltage is uncontrolled when increasing
alternator speed and increases above 15.5 volts,
disassemble and check the alternator for
malfunctioning components.
40
1. If the voltage reading is below 15.5 volts, set
alternator’s rotational speed to 5000RPM and
set the load resistance to achieve maximum
output from the alternator.
2. If the amperage value is more than 70% of the
nominal alternator output as described in
alternator specifications, the alternator is consid-
ered to be working satisfactorily.
55-23
Installation
1. Align the alternator with the alternator mounting 2
holes located on the engine block and brackets.
Use the adjusting/mounting bolts, 2, to secure 1
the alternator to the mounting brackets. Be sure
to install the v-belt, 3, into the drive pulley.
2. Connect all wire terminals, 1, to rear of the
alternator.
2
41
3. Adjust the alternator drive belt deflection by
loosening the mounting bolts and moving the
alternator into or away from the engine block.
Belt deflection should be 10 – 15 mm (0.39 – 0.59
in.) when applying 9 – 11 kg. (20 – 25 lb.) of force
between the crank pulley and the alternator
pulley, 1.
42
55-24
STARTER MOTOR SPECIFICATIONS

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Denso Corporation
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2288000-5120
Current Draw
Under Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500A @ 7.5V
No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . less than 110 amps
No Load RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 RPM
No Load Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5volts
Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overrunning Pinion Clutch
Brush Length
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15mm
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12mm
Brush Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 - 3.6 kg (5.9 - 7.8 lb.)
Commutator Diameter
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35mm
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34mm
Commutator Insulation Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 – 0.85 mm
Armature Runout
Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 - 0.05 mm
Armature Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.02mm
55-25
STARTER MOTOR TROUBLESHOOTING
PINION SHAFT FAILS TO ADVANCE:

Wiring Open circuit, battery, and switch Repair or replace
terminal connections
Open circuit, fuse Replace fuse
Key switch No contact Repair or replace
Starter motor Sleeve bearing burnt out Repair or replace
Lever broken Replace
Solenoid Plunger movement defective or coil Repair or replace
open or shorted
PINION MOTOR ROTATES BUT NO ROTATION TRANSMITTED TO ENGINE:

Starting motor Clutch defective Replace
Orbital gear or planetary gears Replace
damaged
MOTOR ROTATES BEFORE PINION MESHES WITH RING GEAR:

Starter motor Shift lever damaged Replace
Slip ring defective Replace
Pinion teeth worn Replace
Pinion push out position defective Adjust
Engine Ring gear worn Replace
Solenoid Solenoid defective Replace
55-26
PINION MESHES WITH RING GEAR BUT STARTING

MOTOR FAILS TO TURN:
Wiring Line connecting solenoid to battery Repair or replace
broken or defective ground
Lead wire connecting solenoid to Repair or replace
motor tightened improperly
Starting motor Ball bearing locked Replace
Brush worn Replace
Improper installation Reinstall
Brush spring defective Replace
Commutator dirty Clean
Armature of field coil defective Repair or replace
Field coil-to-brush connection Replace
defective
Solenoid Contact not touching properly Replace
Contact contacting surface Replace
roughened
Battery In discharge state Recharge or replace
MOTOR FAILS TO STOP AFTER ENGINE STARTS AND

KEY SWITCH IS TURNED OFF:
Key switch Switch defective Replace
55-27
Op. 55 201
STARTING SYSTEM
The starting system consists of a starter motor
equipped with an electromagnetic starter solenoid, a
key switch, a start relay, several safety switches, and
heavy-duty wiring.
STARTER COMPONENTS
4 5 6 7
2 3
1
15 8
14
10
13 11
20002284
12
43
1. Reduction Uni Cover Starter Motor Assembly
2. Armature Drive Gear The starter motor features a high-speed motor that
3. Motor/Field Coil Housing (Yoke) utilizes a gear reduction unit, an overrunning pinion
4. Permanent Magnet clutch, 12, and permanent magnets, 4, in a field coil,
5. Field Coil 5, for magnetic field induction. The reduction unit
6. Armature consists of a small drive gear, 2, on the motor
7. Brush Spring armature, 6, which drives an idler gear, 14, in the
8. Brush reduction unit. The idler gear is splined to the gear on
9. Plunger the pinion clutch housing, 12. When the starter
10. Solenoid solenoid, 10, is energized, the solenoid plunger, 9,
11. Return Spring pushes the pinion gear, 13, out, engaging with the
12. Pinion Clutch engine flywheel. The starter motor then is turning the
13. Pinion flywheel, which rotates the engine. The use of the
14. Idler Gear gear reduction unit allows use of the compact,
15. Idler Gear Roller Bearing high-speed motor and provides more torque and
power to turn the engine flywheel. The sliding pinion
mechanism is enclosed, resulting in a more durable
mechanism.
55-28
Starter Solenoid
The starter solenoid is an electromagnetic type 2 3
solenoid that is located on the bottom of the starter 1
motor assembly. The solenoid contains two coils, a
pull-in coil, 1, and a hold-in coil, 2. When the key
switch is turned to the “START” position and the
safety start relay is closed (safety switches closed),
current from the battery will energize the solenoid’s
two coils. With the coils energized, the solenoid
plunger, 4, pushes a spring, 5, which will then push
the pinion gear out to engage the flywheel. At the 4
same time, a set of contacts, 3, on the solenoid
become closed, allowing current to flow to the starter SM463-191 5
motor. Closing the contacts also supplies current to
both ends of the solenoid pull in coil, which makes the 44
coil become non-energized. The hold-in coil
continues to engage the pinion gear with the
flywheel.
Pinion Clutch
To prevent the engine from driving the starter motor 1 3
once the engine is running, the pinion gear is 6
equipped with an overrunning clutch. The clutch will 2
disengage the pinion gear from the rest of the starter
components once the engine has been started and
4
the key switch is in the “START” position. The clutch
consists of an outer gear/shell, 1, a cam with tapered
notches, 2, rollers, 3, roller springs, 6, a splined 5
pinion collar/tube that acts as a clutch hub, 4, and the
pinion shaft, 5. As the starter motor engages and
rotates, the rollers are locked against the pinion
collar with the tension provided by the roller springs.
While the rollers are locked, the clutch assembly is
locked, allowing the pinion gear to rotate the 45
flywheel. When the engine starts, the flywheel moves 1. Clutch Gear - Outer Shell
faster than the starter motor and this causes the 2. Cam
rollers to become unlocked. With the rollers 3. Roller
unlocked, the clutch assembly is unlocked, allowing 4. Spline Tube - Inner (Pinion Collar)
5. Pinion Shaft
the pinion gear and shaft to turn independently of the 6. Roller Spring
starter motor.
The clutch is not serviceable and is replaced as a
complete assembly. 4
2
Once the engine is started and the key switch is
released from the “START” position, the solenoid’s
pull in coil becomes energized, pulling the solenoid
plunger in, which disengages the pinion from the
flywheel.
3
1
SM463-189
46
55-29
Removal
1
the battery.
2. Disconnect the wiring harness connections, 2,
from the starter motor, 1.
3. Remove the two (2) bolts, 3, which secure the
starter assembly, 1, to the tractor engine.
2
3
10998316
47
5 6 7
4 8
3
2
1
16
15
14
10 9
11
13
12
20002285
48
1. Felt Washer 9. Solenoid Housing
2. Armature (with Front Bearing) 10. Return Spring
3. Rear Armature Bearing 11. Steel Ball
4. Motor/Field Coil Housing 12. Pinion Clutch
5. Brush Spring 13. Reduction Unit Housing
6. Brush Holder 14. Idler Gear Roller Bearing
7. Brush Cover 15. Roller
8. Through Bolt 16. Idler Gear
55-30
Disassembly
1. Remove the field coil wire, 3, the solenoid 2
terminal, 4.
2. Remove the long through bolts, 1, securing the
motor assembly, 2 to the gear reduction unit
housing.
19985161
3 1
49
3. Slide the motor assembly, 1, from the gear
reduction unit housing, 2. 1
2
4. Remove the two (2) screws, 1, which secure the
brush cover, 2, to the motor/field coil housing, 3.
50
NOTE: Before removing the brush holder, scribe

aligning marks on the brush holder and the
motor/field coil housing. 1
2
5. Use a suitable pair of pliers to remove the
insulated armature commutator brushes, 1, from
the brush holder, 2.
6. Slide the brush holder, 2, from the armature
commutator, 3.
1
3
51
55-31
7. Remove the armature, 1, from the motor/field coil
housing, 2. The rear armature bearing, 3, is a
3
light press fit and it may be necessary to pull the
armature from the housing, gripping on the front 4
bearing, 4.
1 2
52
8. Use an impact tool, 2, to remove the two (2)
screws, 1, securing the gear reduction cover, 3,
to the starter housing.
2
1
3
20002277/20002309
53
NOTE: The pinion gear, 4, and idler gear with roller
bearings, 3, will be free to fall out when the gear 4 1
reduction unit cover, 1, is removed from the starter
assembly, 2. Use care not to lose any of these pieces.
3
9. Carefully remove the reduction unit cover, 1, from
the starter assembly, 2
SM463-199
54
55-32
10. Pull the pinion clutch assembly, 1, from the

reduction unit cover or the starter motor 1
assembly.
SM463-200
55
11. Remove the steel ball, 1, from the center of the
pinion clutch.
SM463-201
56
NOTE: When removing the idler gear and bearing,
be careful not to lose the bearing rollers contained in
the bearing.
1
12. Remove the idler gear and bearing, 1, and pinion
gear from the reduction unit cover, if they were
not removed when the reduction unit cover and
the starter motor housing was separated.
SM463-202
57
55-33
13. Remove the return spring, 1, from the
electromagnetic solenoid. 1
SM463-204
58
14. Remove the three (3) screws, 1, securing the
solenoid cover, 2, to the starter housing. Pry the
cover from the housing.
2
20002306
59
15. Remove the solenoid plunger and spring
assembly, 1, from the starter housing, 2.
2
1
20002307
60
55-34
MILLED CONDITION
EXCESSIVE WEAR
ON 2 OR 3 TEETH
MILLED TOOTH—
METAL BUILDUP
NORMAL WEAR SMALL WEAR WILL NOT PERMIT
PATTERN PATTERN MILLED GEARS
ENGAGEMENT
61
Inspection 3. Inspect the motor housing, brush cover, gear
1. Inspect the gear splines on the pinion clutch, the reduction unit, and starter housing for damage
pinion, the armature, and the intermediate gear such as cracks, fatigue, wear, etc. Replace any
for damaged or missing splines. Replace any damaged parts.
damaged parts. 4. Inspect the brush terminals, battery terminals,
2. Hold the pinion clutch housing and rotate the and motor terminals for corrosion, loose
pinion. The pinion should rotate smoothly, connections or damage. Repair or replace any
although not necessarily easily, in one direction damaged parts.
only. If the pinion can spin in both directions, the
clutch is defective and needs replaced.
55-35
5. Clean and inspect the solenoid plunger contact
ring, 1, and solenoid contacts, 2. Dirty contacts
or pitting may be cleaned with fine grit sandpaper
or a fine abrasive pad. 1
6. Inspect that all bearings rotate freely when
rotated manually by hand and are not damaged
or have excessive play. Replace any damaged
bearings.
20002308 2
62
7. Inspect the armature windings, 1, for burnt,
broken, or loose connections. 1 2
8. Inspect the commutator contacts, 2, for burnt
segments, indicating an open winding.
20002279
63
9. Use a suitable measuring device to measure the
commutator diameter. The minimum commuta-
tor diameter is 34.0 mm (1.339 in.). If the
commutator is worn beyond these specifications,
replace the armature.
19985170
64
55-36
10. Inspect the mica insulating valleys, 2, between

the commutator contacts, 1, for uneven wear. 2 1
Use a suitable measuring device to check the
distance, 3, between the top of the contact to the
bottom of the insulating valley. The distance
should be 0.5 – 0.8 mm (0.020 – 0.031 in.). If the
distance is not within these specifications or 3
there is uneven wear, the insulating valleys may UNACCEPTABLE
be undercut with a suitable file.
20002267 CORRECT
65
NOTE: If not previously removed, the armature
bearings will need to be removed for this test. 3 1
11. Place the armature, 1, in a set of precision 5

V-blocks, 2, and use a dial indicator, 3, to
measure commutator, 4, runout and shaft, 5,
runout. Commutator runout should not be more
than 0.2 mm (0.008 in.). Shaft runout should not
be more than 0.05 mm (0.002 in.).
2
20002266 4 2
66
NOTE: When measuring the brush length, remove
the brush from the brush support and measure the
middle portion of the brush.

length of the four armature brushes. Compare
the measurement of each brush with brush
length specifications. If the brush is not within
specifications or is damaged in any way, replace
the brushes.
67
55-37
13. Test the brush spring tension by connecting a
spring balance to the brush spring and pulling 5.9 lbs.
until the spring moves. Observe the reading
indicated on the spring balance. If the reading is
between 2.7 – 3.6 kg (5.9 – 7.8 lb.), the spring
tension is within specifications. Otherwise,
replace the brush springs. 7.8 lbs.
68
ELECTRICAL TESTING
Armature
2
1. Use a growler, 2, to inspect the armature coil, 1,
for short circuits. Replace if the armature is
shorted.
69
2. Use an ohmmeter to test for continuity in the
armature coil, 1.
3. Touch one ohmmeter test probe to a commutator
contact, 2. Touch the ohmmeter test probe to an 2
adjacent commutator contact.
4. Observe the ohmmeter. Repeat the test on each 1
adjacent commutator contact. Little or no
resistance indicates that there is continuity and
the armature coil is good. High resistance
indicates that the armature is defective and
needs replaced.
20002280
70
55-38
5. If the armature is tested OK, touch one ohmmeter

test probe to a commutator contact, 1. Touch the
other test probe to the armature shaft, 2.
1
2
6. Observe the ohmmeter. A high resistance
reading indicates the armature is good. Little or
no resistance indicates that the armature is
19985173
71
Brush Holder
insulated brush holder, 1, and the other test 1
probe to the brush holder plate, 2.
2. Observe the ohmmeter. Repeat the test for the
opposite insulated brush holder.
3. A reading high resistance indicates no continuity 2
and the brush holder is good. Little or no
the brush holder is defective and needs replaced.
72
Field Coil
1. Use an ohmmeter to test the field coil.
2. Touch one ohmmeter test probe to one of the field
coil brushes. Touch the other test probe to the
remaining field coil brush.
3. Observe the ohmmeter. Little or no resistance
indicates continuity and that the field coil is
functioning properly. High resistance indicates
the field coil is defective and needs replaced.
73
55-39
NOTE: Paint on the field coil/motor housing will give
a false reading when testing to see if the field coil is
grounded. Be sure to remove paint from the field
coil/motor housing.
4. If the previous test indicated the field coil was not

defective, touch one ohmmeter test probe to one
of the field coil brushes, 1. Touch the other test
probe to the field coil housing, 2.
5. Observe the ohmmeter. If the reading shows high 1
resistance, indicating no continuity, the field coil 2
is not grounded and is functioning properly. If
there is little or no resistance indicating
continuity, the field coil is defective and needs 74
replaced.
Starter Solenoid
NOTE: The following test should be performed with
the starter assembly partially assembled.
NOTE: If solenoid will not be disassembled after this

test, apply white lithium grease to the armature drive
gear, pinion clutch, idler gear and roller bearings, and
the pinion clutch steel ball and return spring.
1. Install the solenoid plunger and spring assembly,
1, into the starter housing, 2.
2
1
20002307
75
2. Install the solenoid cover and gasket to the
starter housing. Install the three (3) screws, 1,
securing the solenoid cover, 2, and gasket to the
starter housing.
1
2
20002306
76
55-40
3. Install the return spring, 1, into the solenoid.

1
77
4. Install the steel ball, 1, into the center of the
pinion clutch.
78
5. Install the pinion clutch, 5, in the starter housing.
Make sure the rear clutch bearing is completely 4 1
seated in the housing.
6. Grease the idler gear bearing with petroleum jelly
3
and install the gear, 3, and bearing onto the
starter housing. Align the bearing and gear so
that it meshes with the pinion clutch and is
aligned with the hole in the housing for the pin
which the bearing rides on.
7. Install the pinion gear, 4, in the proper recess in 2
the reduction unit cover, 1, as the cover is being
installed onto starter motor housing.
79
55-41
8. Secure the gear reduction cover, 2, with the two
(2) retaining screws, 1. 1
20002277
80
CAUTION
Do not perform this test for more than 3 - 5 3 1
seconds at a time, as damage may occur to the 2
solenoid or other components.
NOTE: Be sure to use test leads that have 14 awg

wire or thicker for this test.
9. Connect a test lead from the positive (+) terminal

of a 12-volt power source to the starter switch
terminal, 1, (spade terminal) of the starter.
SM463-216
10. Use another test lead to connect the negative (−)
terminal of the 12-volt power source to the starter 81
housing, 2.
11. Connect a second negative (--) test lead from the
12-volt power source to the field coil terminal, 3.
This completes the circuit to send current to the
hold-in and pull-in coils of the solenoid.
12. Observe the starter pinion. The solenoid should
have caused the pinion to jump forward when the
third test lead was connected to the field coil
terminal. This indicates the pull-in coil is working
properly.
13. Remove the test lead to the field coil terminal, 3,
and observe the starter pinion. The solenoid 1
3 2
should keep the pinion extended when the third
test lead is removed. This indicates the hold-in
coil is working properly.
14. If the solenoid fails to perform as described,
replace the solenoid assembly.
82
55-42
5 6 7
4 8
3
2
1
16
15
14
10 9
11
13
12
20002285
83
Assembly
NOTE: Use white lithium grease to lubricate parts
indicated. 2
1. Install the solenoid plunger, 1, into the starter

housing, 2.
1
20002307
84
55-43
starter housing.
1
2
20002306
85
3. Grease and install the return spring, 1, into the
solenoid. 1
86
4. Grease and install the steel ball, 1, into the center
of the pinion clutch.
87
55-44
5. Grease and install the pinion clutch, 5, in the

starter housing. Make sure the rear clutch 4 1
bearing is completely seated in the housing.
6. Grease the idler gear bearing and gear and
3
install the gear, 3, and bearing onto the starter
housing. Align the bearing and gear so that it
meshes with the pinion clutch and is aligned with
the hole in the housing for the pin which the
bearing rides on.
7. Install the drive gear, 4, in the proper recess in the 2
reduction unit cover, 1, as the cover is being
88
20002277
89
55-45
9
5 7
10
1
8
4
20002287 2
90
1. Front Armature Bearing 6. Brush
2. Armature 7. Brush Holder
3. Rear Armature Bearing 8. Brush Cover
4. Motor/Field Coil Housing 9. Bolt
5. Brush Spring 10. Through Bolt
9. If removed, install the front and rear bearings, 1, 11. Install the field coil brushes, 6, into the brush
3, onto the armature, 2. holder, 7, by holding the brush springs, 5, away
as the brush is being inserted into the insulated
10. Install the armature, 2, into the motor/field coil
brush holder.
housing, 4. Be sure that the rear bearing, 3, is
properly seated in the motor housing. 12. Install the brush holder, 7, onto the armature
commutator.
NOTE: When installing the field coil brushes, be sure
that the aligning marks made on the brush holder and 13. Secure the brush cover, 8, to the brush holder, 7,
motor/field coil housing will line up when the brush using the two (2) retaining bolts, 9.
holder is installed onto the armature commutator.
55-46
NOTE: Be sure the aligning marks made on the

starter housing and motor/field coil housing line up 1
when installing the motor assembly to the starter 2
assembly.
14. Install the motor assembly, 1, into the starter

assembly, 2.
91
15. Secure the motor assembly, 2, to the starter
assembly using the two (2) long through bolts, 1. 2
1
19985161
92
16. Install the field coil wire, 1, the solenoid terminal,
2.
1
2
93
55-47
No Load Test
NOTE: Before installing the starter motor to the Ammeter
tractor engine, it is recommended that a no load test
be performed on the starter motor. A
Switch
B
CAUTION S
M
Do not operate the starter for than 30 seconds at Voltmeter
Battery V
a time.
1. Connect a battery and switch to the battery

terminal of the starter and the “S” terminal of the
solenoid.
2. Connect an ammeter between the positive (+) 94
battery terminal of the battery and the battery
terminal of the starter solenoid.
3. Connect a voltmeter, after the ammeter, between
the positive (+) lead from the battery and the
negative (--) lead from the battery.
4. Close the switch and record the readings
indicated on the ammeter and voltmeter.
5. Test starter components if any abnormal
operation is noted.
6. Service limits are 11.5 volts, 110 amps maximum
at 4000 RPM.
Installation
2
1. Install the starter motor, 2, to the engine and
secure using the two (2) retaining bolts, 1. Be
sure all ground terminals are connected to the
bottom starter bolt.
2. Connect the tractor wiring harness connections,
to the starter.
battery.
3
1
10998316
95
55-48
SECTION 55 -- ELECTRICAL -- CHAPTER 5
DX40--DX45 With Cab
CONTENTS

Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fuse Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Heat/ Accessory/ Run Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Start Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Multifunction Stalk Switch (Lights, Turn Signals, Horn) . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
55 404 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
55 404 Taillight/Rear Flasher Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front Flasher Warning Light/Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Cab Work Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
55-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
“Off” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
“On” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
55 408 Transmission Range Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Extended Position (PTO “ON”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Retracted Position (PTO “OFF”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
55 408 Mid PTO Safety Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
(DA) Series Relay Panel Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
55-2

“HI”, “LOW”, Cruise Control, Fuel Shutoff, PTO Safety, Glow Plug Lamp,
Flasher Cutoff, Park Brake Interface, Front Work Lights, and HVAC Relays . . . . . . . . . . 33
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Headlight, Neutral Start, and Cab Power Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation (All Relays) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Module Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Diode Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Park Brake Safety Alarm (Buzzer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Glow Plug Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
55-3

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hi/Low Transmission Range Switch (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Optional Joystick Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hi/Low Transmission Range Solenoid (HST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cab to Tractor Harness Main Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
55-4

Bolt Grade Pitch Foot-
Foot Newton Pitch Foot-
Foot Newton
Newton-
4T, 4 3.6-5.8 4.9-7.9
M6 7T, 7 1.0 5.9-9.4 7.9-12.7 ------ ------ ------
8T, 8, 11 7.2-10 9.8-13.6
4T 7.2-14 9.8-19 12-17 16.3-23
M8 7T 1.25 17-22 23-29.8 1.0 19-27 25.7-36.6
8T 20-26 27.1-35.2 22-31 29.8-42
4T 20-25 27.1-33.9 20-29 27.1-39.3
M10 7T 1.5 34-40 46.1-54.2 1.25 35-47 47.4-63.7
8T 38-46 51.5-62.3 40-52 54.2-70.5
4T 28-34 37.9-46.1 31-41 42-55.6
M12 7T 1.75 51-59 69.1-79.9 1.25 56-68 75.9-92.1
8t 57-66 77.2-89.4 62-75 84-101.6
4T 49-56 66.475.9 52-64 70.5-86.7
M14 7T 2.0 81-93 109.8-126 1.5 90-106 122-143.6
8T 96-109 130.1-147.7 107-124 145-168
4T 67-77 90.8-104.3 69-83 93.5-112.5
M16 7T 2.0 116-130 157.2-176.2 1.5 120-138 162.6-187
8T 129-145 174.8-196.5 140-158 189.7-214.1
4T 88-100 119.2-136 100-117 136-158.5
M18 7T 2.0 150-168 203.3-227.6 1.5 177-199 239.8-269.6
8T 175-194 237.1-262.9 202-231 273.7-313
4T 108-130 146.3-176.2 132-150 178.9-203.3
M20 7T 2.5 186-205 252-277.8 1.5 206-242 279.1-327.9
8T 213-249 288.6-337.4 246-289 333.3-391.6
55-5
Op. 55 100
The DX40 and DX45, cab, electrical system is a
12-volt negative (--) ground system consisting of 5
main wiring harnesses.
COMPONENT LOCATION AND FUNCTION
10
2 3
4 11
14 15
8
A
7 6D
6B
1 6C
6A
D 19
13 B 12 20
56066100
5
21
18
9
23 C
16
24
22
17
56066101
55-6
1. Battery -- Located under the hood, in front of the 12. Starter – Located on the left side of the engine;
radiator; electrical power source. Group 47 rotates the engine for starting.
2. Main Fuse (50 Amp.) -- Located on the left side 13. Alternator (55 Amp.) – Located on the left side
of the engine directly above the starter; protects of the engine; generates power to charge the
the entire electrical system from damage due to battery.
excessive current.
14. Engine Oil Pressure Switch – Located in front
3. Fuse Block – Located in the lower steering of the cylinder head; provides warning of low
wheel console panel; contains fuses that protect engine oil pressure.
individual circuits from damage due to excessive
15. Engine Coolant Temperature Sending Unit –
current.
Located in the thermostat housing on the front
4. Relay/Diode Panels – Located on both sides of left side of the engine; warns the operator of high
the steering wheel column; houses relays operating temperatures.
utilized by individual circuits and diodes which
16. Fuel Level Sending Unit – Located inside the
direct current within a circuit to allow the use of
fuel tank; sends a signal indicating fuel level to
one wire within multiple circuits to control a relay.
the instrument panel.
5. Key Switch – Located on the right side of the
17. Fuel Shutoff Solenoid – Located on the right
operator’s console; used to switch battery power
side of the engine; shuts off the fuel flow to the
on or off to the tractor’s electronic circuits, supply
injection pump to stop the engine.
power to the engine glow plugs, or to start the
tractor. 18. Engine Glow Plugs – Located on the right side
of the cylinder head, adjacent to the fuel
6. Safety Start Switches (4) – Range gear (A) HST
injectors; aid in engine startup by warming the air
transmission, rear PTO (B), mid PTO (if
in the combustion chamber.
equipped) (C), and the operator’s seat switch
(D); will not allow the tractor to start with the 19. Park Brake Switch – Located under the left
transmission or the PTO engaged, or without an platform; actuates with the parking brake
operator in the operator’s seat. mechanism; indicates when the parking brake is
engaged by illuminating a light on the instrument
NOTE: The park brake switch also lights the parking
panel.
brake indicator light on the instrument panel when
the parking brake is engaged. 20. Brake HST Cruise Release Switch – (Deluxe
Only) – Located on the upper brake pedal
NOTE: The tractor may be started without the support, underneath the left console panel;
operator being seated when the parking brake lever releases the HST speed control when the brakes
is engaged. are applied.
21. HST Cruise Control Switch – Located on the
7. Headlights – Four lights, located in the front grill right fender; controls current to the speed control
of the tractor, used to illuminate the area in front magnet.
of the tractor.
22. HST Control Magnet – Located on the right
8. Taillights/Directional Signals/ Flasher Warn- transmission side of the steering column; locks
ing (Hazard) Lights – Located on both sides of the HST linkage in place to set constant
the cab; provide warning during transportation transmission speed.
and emergency.
23. HST Hi/Lo Range Selector Switch – Located
9. Instrument Panel – Located in the center of the on the right fender; momentary toggle switch
dash panel; houses gauges and indicator lights used to select either of the two different HST gear
that monitor tractor functions. ranges. Located on optional front two spool valve
10. Light Switch – Located on the left side of the control handle.
dash panel; switches the headlight, taillight and 24. Auxiliary Electrical Power Socket – Located at
the instrument panel lights on or off. the right rear of the cab; provides electrical
11. Hazard (Flashing Warning Lights) Switch – current for any auxiliary 12 volt electrical item (15
Located on the left side of the dash panel; amp maximum).
switches the flashing warning (hazard) lights on
and off.
55-7
Op. 55 100
WIRING HARNESSES, Figures 1 and 2

A. Hood (Front lights)
B. Front Main (Includes engine area, starter, alternator,
glow plugs, fuel solenoid)
C. Panel (Includes relay and fuse areas)
D. Rear Chassis
E. Cab
Grounds
1. Negative battery post to the right side of the frame.
2. Starter mounting bolt
3. Left front cab frame
4. Left rear cab frame
5. Left side behind rear tire on HPL housing
2
1
50043929
86064523
3 4
50043931
86064524
5 6
55-8
ELECTRICAL SYSTEM COMPONENTS

WARNING
Before working on any component of the
electrical system, the negative (--) battery cable
should be disconnected from the battery, as
electrical shock or damage to the system
components may occur. Some testing requires
12-volt power; use caution whenever power is
used.
BATTERY
The tractor is equipped with a BCI group 47, 12-volt
battery with a minimum cold cranking ability of 600
amps at 0°F (--18°C).
Make sure the battery connections are tight and free

of corrosion. A solution of baking soda and water may
be used to wash the outside surface and terminals of
the battery when necessary. However, make sure the
solution does not get inside the battery. After
cleaning, wash the battery with clean water, then
apply a small amount of petroleum jelly to the
terminals to prevent corrosion. 86064532
In freezing temperatures, a good battery charge 7

must be maintained. If the battery becomes
discharged or run down, the electrolyte becomes
weak and may freeze, causing damage to the case.
If you must add water, use distilled water. Add the
water just before using the tractor so that the water
will mix with the electrolyte during the charging
process, thus preventing the water from freezing.
To determine the battery charge, check the specific

gravity of the electrolyte.
55-9
Checking the Electrolyte Level
NOTE: Check the battery electrolyte level after every
50 hours of operation.
WARNING
Always check the electrolyte level with the tractor
engine off, as an explosive gas is produced inside
the battery when the alternator is charging. Do not
use an exposed flame and do not smoke when
checking the battery electrolyte level.
To check the battery electrolyte level:

1. Clean the top of the battery, then remove the vent
plugs.
2. Add distilled water if the electrolyte level is low.
The level is correct when the liquid is 6.35 mm
(1/4 in) above the plates.
NOTE: Keep distilled water in a non-metallic
container that is clean and well-covered.
3. Install the vent plug after making sure the vent
holes are not blocked. At below freezing
temperatures, run the engine for a period of time
after adding water, allowing the battery to charge,
which prevents the water from freezing.
Removal
1. Release and lift the tractor engine cover.
2. Disconnect the negative (--) battery cable. 1
3. Disconnect the positive (+) battery cable.
4. Remove the hardware, 1, securing the battery.
5. Carefully remove the battery from the tractor.
IMPORTANT: Crossing the battery terminals may
cause damage to the electrical system.
Installation
86064532
NOTE: When replacing the battery, use only a BCI
group 47, 12 volt battery. Make sure the battery fits 8
the battery tray correctly and is properly secured with
the mounting hardware. Never use a battery that
does not fit properly in the battery tray. Do not
overtighten the battery securing hardware. Do not
overtighten the battery cables.
1. Place the battery in the battery tray with the
battery posts towards the front of the tractor.
2. Use the battery hold down hardware, 1, to secure
the battery in the battery tray.
3. Connect the positive (+) cable to the positive
terminal.
4. Connect the negative (--) cable to the negative
terminal.
55-10
MAIN FUSE
The main fuse is a 50-amp maxifuse, 1, located on 1
the left-hand side of the engine and positioned above
the starter. This fuse protects the tractor’s entire
electrical system.
30997565
9
Replacement
2
To replace the main fuse:
1. Unplug the connector to expose the fuse.

2. Remove the old fuse, 2, from the fuse holder and
replace.
IMPORTANT: Always replace this fuse with a similar
50 amp fuse; DO NOT increase amperage rating.
56064531
10
55-11
FUSE BLOCKS 86064815

The tractor main fuse block is located in the lower 1
steering wheel console panel.
The cab fuse block is located in the upper rear of the

cab, centered above the rear window.
To gain access to either fuse panel, remove the two

screws that retain the panel cover, 1.
1
10054361
11
7 6 5 4 3 2 1
86065584 Main Fuse Block
12
27 26 25 24 23 22
86065585 Cab Fuse Block

13
55-12
From left to right the fuse block contains the following fuses:
FUSE # and SIZE FUNCTION

TRACTOR Main Fuse Block
Fuse #1 – 7.5 Amp Glow Plugs, Alternator, Cab Power
Fuse #2 – 10 Amp Safety Start, Fuel Shutoff
Fuse #3 – 10 Amp Turn Signals
Fuse #4 – 10 Amp Work lights, Headlights, Park Brake Alarm
Fuse #5 – 7.5 Amp Instrument Panel, Cruise Control, Range High/Low
Fuse #6 – 15 Amp Hazard lights, Front Work lights, Radio, Cab Dome light (Input to 2 amp fuse #22)
Fuse #7 – 15 Amp Horn, Park Brake Alarm
CAB Fuse Block
Fuse #22 – 2 Amp Radio( Memory), Cab Dome light
Fuse #23 – 10 Amp Radio (Functions)
Fuse #24 – 20 Amp HVAC
Fuse #25 – 15 Amp Beacon, Auxiliary Power Socket
Fuse #26 – 15 Amp Front Wiper, Rear Wiper,
Fuse #27 – 20 Amp Cab Work lights
55-13
KEY SWITCH
The key switch is located on the right side of the
operator’s console. The key switch has three
key-operated positions, which are: STOP, 1,
HEAT/ACCESSORY/RUN, 2, and START, 3. Turning
the key clockwise from the stop position will align the
electrical contacts within the key switch. With the
contacts aligned, the circuit is closed and the battery
current will flow through the circuit. 2
1
In the STOP position, 1, there is no battery power 3
supplied to electrical circuits and the key may be
removed from the switch to prevent unauthorized
use of the tractor. The STOP position, 1, also stops 86064795
the tractor engine, when running. When the key is in
the HEAT/ACC/RUN position, 2, battery current 14
flows to the engine glow plugs to aid in starting the
engine when the engine is cold. The HEAT/ACC/
RUN position, 2, also allows current to flow from the
battery to the tractor accessories without the engine
running. The switch will also be in this position while
the tractor is running. When the key is in the START
position, 3, power is supplied to the starter motor to
crank and start the engine. The key switch is spring
loaded and will return from the START position, 3 to
the HEAT/ACC/RUN position, 2.
The key switch is not serviceable and must be

replaced if troubleshooting determines the switch is
defective.
Removal
2. Remove the two side and middle retaining
screws, 1, from the side panel, 2, and remove the
right side panel from the tractor.
3. Unplug the connector from the key switch.
4. Remove the retaining nut from the switch and
remove switch from the panel. 2
66064539
15
55-14
Terminal Identification
A Start
B 12 V Input
C ACC Terminal
D 12 V Input
Testing
Use an ohmmeter to test each position of the key
Stop Position (Not Shown)

1. With the key switch in the stop position, continuity 30002125
should not exist between any of the terminals. If
16
continuity exists between any of the terminals
while the switch is in the “stop” position, the key
switch is defective and needs replaced.
Heat/ Accessory/ Run Position
When the key switch in the “Heat/ ACC/ Run”
position, continuity should exist between the “B” and
“C” terminals.
1. Make sure the switch is in the “Heat/ACC/Run”

position.
terminal “C”.
show little or no resistance indicating that 30002126
17
terminal B” and terminal “C”, the key switch is
NOTE: Continuity should not exist between
terminals A and D in the “Heat/ACC/Run” position.
Start Position
Make sure the key switch is in the “Start” position.

terminal “C”.
terminal “B” and terminal “C”, the key switch is
30002126
18
55-15
3. Following the procedure outlined in the previous
2 steps, test terminals “A” and “D”. With the Key
in the “Start” position, continuity should exist
between the “A” and “D” terminals.
Installation
1. Place key switch in side panel and align switch
with the slot in the panel.
2. Install and tighten nut on switch.
3. Plug wire harness connector to switch
4. Install right side panel with four retaining screws.
30002127
5. Reconnect the negative (--) battery cable to the
negative (--) battery terminal. 19
MULTI FUNCTION STALK SWITCH

(LIGHTS, TURN SIGNALS, HORN)
The multi function stalk switch is located on the left 1
side of the dash .
The switch has the following functions:
1. Light Switch (Rotary operation)

1st position -- “OFF”
2nd position -- Position Lights
3rd position – Headlights
Push downwards on stalk – Headlights 86064802
Lift upwards on stalk -- Headlights will flash to full 20

beam lights, spring loaded to return to original
position.
2. Turn signal Switch

Forward Position -- Right Turn
Rearward Position – Left Turn
3. Horn Switch
Push in on stalk to activate horn
NOTE: The light and turn signal circuits will not

function unless the key switch is place in the
“ACC/RUN” position. The horn will function with key
switch in any position.
55-16
Removal
screws, 1, from the side panels, 2, and remove
the panels from the tractor.
3. Tilt steering column fully rear rearward, before 1
trying to remove top panel.
4. Remove instrumental panel from top consol
panel. 2 3
5. Remove the handle throttle knob also disconnect
hazard and work light switches. 1
6. Remove the two side retaining screws, 3, and lift
the top panel, 4, from the tractor.
7. Unplug the connector from the stalk switch.
2
66064539
8. Remove the three retaining screws with nuts
from the switch and remove switch from the 21
mounting bracket.
Switch Testing
1 2 3 4 5 6
Switch
Function Pin Continuity
Horn 1 and 4
Stalk switch 2 and 5
pushed down- (With rotary part of switch in
wards headlights position)
Headlights 2 and 6
Position Lights 2 and 7
Left Turn 3 and 8 7 8 9
86064526
Right Turn 3 and 9
22
Use an ohmmeter to test each position of the light
Installation, Figure 21
1. Install the stalk switch using the three retaining
screws with nuts to the mounting bracket.
2. Plug the connector into the stalk switch.
3. Tilt steering column fully rearward, before trying
to install top panel.
4. Place the top panel, 4, in place and install the two
side retaining screws, 3.
5. Install hand throttle knob while connecting
hazard and work light switches.
6. Install instrument panel into top console panel.
7. Install the side panels, 2, and secure with the two
side and middle retaining screws, 1.
8. Connect negative battery (--) cable to the
55-17
HEADLIGHTS
If any of the four headlights fails to operate, the bulb
must be replaced. To change a bulb:
1. Open the tractor hood.

2. Rotate the bulb socket counterclockwise a
quarter turn and remove the socket from the
housing.
3. Pull the defective bulb straight out of the socket.
4. Install a new bulb in the socket by pushing it
straight in until it bottoms.
IMPORTANT: Be careful not to touch the new bulb 23
with bare fingers, as oils from the skin can shorten the
life of the bulb. Use a protective cloth or gloves when
installing halogen bulbs.
5. Re-install the socket into the housing and rotate

it clockwise a quarter-turn to lock it into place.
NOTE: Replace the defective bulb with a size 894
halogen bulb.
55-18
Op. 55 404
TAILLIGHT/REAR FLASHER LIGHT

The taillights are located on the left and right rear of
cab uprights. The taillights illuminate the rear of the
tractor to provide warning to approaching vehicles.
NOTE: The same procedure is used for both sides.
To replace a taillight bulb: 4
1. Pull taillight lens, 1, out of the rubber lamp 2

housing, 2.
86064830
24
bulb.
86064831
25
5
1. Pull flasher/turn lens, 4, out of rubber housing, 2.

bulb.
86064832
26
55-19
FRONT FLASHER WARNING LIGHT/TURN

SIGNALS
1. Remove the two screws, 1, retaining the signal

lens and remove the lens.
1
86065587
27
3. Install the new bulb by pushing it in to the socket
bulb.
86065588
28
CAB WORK LIGHTS
NOTE: The same procedure is used on all sides.
1
1. Remove the defective bulb assembly, 1, by
rotating it counterclockwise and pulling it out of
the rear of the light housing, 2.
2. Release the retaining tabs and remove bulb
assembly.
3. Reconnect new bulb assembly onto the harness,
making sure the retaining clips are securely
locked into position. 86065586
2
4. Place new bulb assembly into the rear of the light
housing, 2, rotating it clockwise until it locks into 29
place.
IMPORTANT: Be careful not to touch the bulb with
bare fingers. Oil from the fingers can shorten the life
of the bulb. Use protective cloth or gloves when
installing bulb.
NOTE: Replace the defective bulb with a new GE886

single element 50 Watt, Halogen.
55-20
HAZARD LIGHT SWITCH

The hazard light switch, 1, is a two-position,
rocker-type switch located on the left-hand side of
the tractor dash panel.
The two positions of the hazard light switch are:

• OFF POSITION (Safety symbol protruding out of
switch) 1
• ON POSITION (Safety symbol pushed into
switch)
An internal indicator bulb flashes when the hazard

light switch is in the “on” position.
56064563
The hazard lights will operate regardless of the key
30
switch position.
Removal
left side panel from the tractor. 2
3. Unplug the connector from the switch.
4. Squeeze the retaining tabs on the switch and
push switch upwards from underneath the top
panel.
66064539
31
55-21
Testing
hazard light switch for electrical continuity.
“Off” Position
terminal 2.
replaced.
30002193
32
terminal 7.
defective and the switch needs replaced.
30004012
33
“On” Position
terminal 3.
replaced.
20004013
34
55-22
terminal 6.
replaced.
20004014
35
terminal 7.
Installation
1. Insert the hazard light switch into the dash panel
until the locking tabs click into place. 20004012
2. Connect the wiring harness to the hazard light 36

switch.
3. Install the left side panel using the four retaining
screws.
55-23
Op. 55 408
TRANSMISSION RANGE SAFETY SWITCH

The transmission range safety switch, 1, is a
single-pole, push-button type switch located under-
neath the left side operator’s platform. When the
transmission is in high or low range, the contacts in 1
the switch are open, not allowing the tractor to start.
When the transmission is in the neutral range
position, the contacts in the switch are closed
NOTE: The transmission range safety switch may be

tested for continuity without removing the switch from
the tractor, but it is recommended that the switch be
removed for testing. Follow the same test procedure 30004047 HST
outline when the switch is removed from the tractor.
37
Removal
2. Disconnect the transmission range safety switch
leads from the wiring harness.
3. Remove the transmission range safety switch, 1,
with the rubber washer, 2, from the transmission
case. 2
NOTE: The HST range shift rail, operates the 3
transmission range safety switch. Grooves in the shift
rails accept the balk pin, extending the plunger in the 30002200
safety switch, when the range control lever is in neutral.
This completes the circuit, allowing the tractor to start. 38
4. Use a pencil magnet to remove the balk pin, 3, from

the transmission range safety switch hole in the
transmission case. Inspect the balk pin, 3, for
damage.
55-24
Testing
transmission range safety switch for electrical continuity.
Extended Position
EXTENDED
1. With the transmission range safety switch in the
“extended” position, touch one of the test probes
to the one switch lead. Touch the other test probe
to the other switch lead.
continuity exists between the two leads. If
continuity does not exist, the switch is defective
and needs replaced.
Retracted Position (Not Shown) 30002201

3. Using an ohmmeter, continuity should not exist 39
between the two leads. If continuity exists
between the two leads while the switch is in the
needs replaced.
Installation
1. Insert the balk pin, 3, into the transmission range 1
safety switch hole in the transmission case.
2. Install the transmission range safety switch, 1,
with the rubber washer, 2, into the transmission
case.
3. Connect the wiring harness to the transmission
range safety switch leads. 2
4. Connect the negative (--) batter cable to the 3
30002200
40
55-25
REAR (MAIN) PTO SAFETY SWITCH

The rear (Main) PTO safety switch, 1, is a double 1
pole, single throw, push button type switch. This
switch is located underneath the left side of the cab
platform, on the PTO linkage.
When the PTO is disengaged:

One set of contacts are closed – Completing the
safety start circuit
One set of contacts are open – Opening the park
brake safety alarm circuit
When the PTO is engaged : 30002199
One set of contacts are open – Opening the 41

safety start circuit
One set of contacts are closed – Completing the
park brake safety alarm circuit
Removal
2. Disconnect the rear PTO safety switch leads
from the wiring harness.
3. Remove the rear PTO switch by pressing in on
the locking tabs and sliding the switch upward out
of the support bracket.
Testing
rear PTO safety switch for electrical continuity.
Extended Position (PTO “ON”)

EXTENDED
With the PTO switch in the extended “ON” position:
Across terminals A and B = No Continuity

Across terminals C and D = Continuity
56064541
42
55-26
Retracted Position (PTO “OFF”)
RETRACTED
With the PTO switch in the retracted “OFF” position:
Across terminals A and B = Continuity

Across terminals C and D = No Continuity
Installation
1. Push the switch into the opening in mounting
plate until locking tabs lock in position.
2. Connect wire harness to switch
3. Reconnect the negative (--) battery cable to the 56064542
negative (--) battery terminal 43
Op. 55 408
MID PTO SAFETY SWITCH (Optional)

The mid PTO safety switch, 1, is a double-pole,
single throw-style switch located on the control lever 1
pivot bracket. The switch, consisting of a rubber-
booted, push-button actuator and four rubber coated
terminals, monitors the position of the mid PTO
linkage and is activated by the mid PTO lever.
Removal
2. Disconnect the mid PTO safety switch from the 2
wiring harness. 10998387
3. Remove the two switch mounting bolts, 2, and 44
pull the switch away from the tractor differential
housing.
Testing
mid PTO safety switch for electrical continuity.
Extended Position
With the mid PTO safety switch in the “extended”
position, continuity should not exist between any of
the four terminals. If continuity exists between any of
the four terminals while the switch is in the “extended”
55-27
Retracted Position
1. Push the switch to the retracted position.

30002195
45
3. Using an ohmmeter in the same matter, touch
one of the test probes to terminal, C. Touch the
other test probe to terminal, D.
30002196
46
Installation
1. Install switch to mounting bracket using two
machine screws and nuts.
2. Connect wire harness connector to switch
55-28
SEAT SAFETY SWITCH

Description
The seat safety switch, 1, is a double pole, button
type switch mounted to the bottom side of the seat
pan. When the operator is not seated, the switch
contacts are open and when the operator is seated,
the switch contacts are closed. 1
20054397
47
Removal
NOTE: The seat safety switch may be tested by
removing the switch harness from the switch and
placing ohmmeter test leads on the switch terminals.
Push down on the middle of the seat to check for
switch continuity However, it is recommended to
remove the seat switch from the seat for testing.
1. Tilt the seat forward to reveal the seat safety

switch.
2. Disconnect the seat switch harness from the
switch.
3. Rotate the switch counterclockwise to release
the locking tabs and remove the switch from the
seat.
55-29
Testing
seat switch for electrical continuity.
Extended Position
With the switch in the “extended” (OUT) position
continuity should not exist between any of the four
terminals. If continuity exists between any of the
switch terminals while the switch is in the “extended”
position, the switch is defective and needs to be
replaced.
Retracted Position
With the switch in the “retracted” (IN) position,
continuity should exist across the following termi-
nals:
Check continuity between Terminals #1 and #3.
50054398
48
Check continuity between Terminals #2 and #4.
If continuity does not exist between the two sets of

terminals while the switch is in the “retracted”
position the switch is defective and needs to be
replaced.
Installation
1. Tilt the seat forward to reveal the bottom of the
seat.
2. Rotate the switch clockwise to retain the locking
tabs. 50054399
3. Connect the seat switch harness to the switch. 49
55-30
Op. 55 408
PARK BRAKE SAFETY SWITCH

The park safety switch, 1, is a double-pole, single
throw-style switch located on the brake control lever 1
pivot bracket. The park brake switch is located
beneath the left cab platform.
Testing
parking brake safety switch for electrical continuity.

1. With the park brake safety switch in the
“extended” (“off”) position, continuity should not
exist between any of the four terminals. If
continuity exists between any of the four
terminals while the switch is in the “extended”
replaced.
56064556
50
Retracted Position
1. Push the park brake safety switch into the

“retracted” position.
51
to terminal, C. Touch the other test probe to
terminal, D.
30002196
52
55-31
RELAYS
10
1 2 3
11 12
13 4 5 6
7 8 9
56066102
53
(DA) Series Relay Panel Identification
Relay Identification
1. PTO Safety Start (R1) (R#) Wiring Schematic Identification
2. Glow Plug Lamp (R4)
3. Range Low Shift (R7)
4. Fuel Shutoff (R2)
5. Cruise Control Latch (R8)
6. Flasher Cutoff (R5)
7. Park Brake Interface (R3)
14
8. Range High Shift (R6)
9. Front Headlights (R14)
10. Neutral Start (R9)
11. Glow Plug Power (R10)
12. Cab Power (R12)
13. Glow Plug Timer (R13)
14. HVAC ( R15) (located near cab fuse block, top rear
of cab) 86065585
54
55-32
Relays are used to automatically complete (close) a
circuit. The relays are located underneath the
steering column console panels on both the left and
right sides of the steering wheel. A relay contains two
parts of a circuit. One part, the control circuit, uses
current to energize a coil. The other part, the function
circuit, is a switch. When energized, the coil of a relay
becomes an electromagnet opening or closing a
single circuit or directing current from one circuit to
another, depending on the type of relay.
The function circuits are normally open when no

current is being supplied to the coil. If a circuit with an
SPST relay is energized with current on the DX
series tractor, the switch becomes closed and the 55
circuit is completed. The relay is then considered to
be latched.
Removal
panel. 2 3
7. All relays are now accessible. 2
66064539
56
TESTING-MICRO RELAYS
“HI”, “LOW”, CRUISE CONTROL, FUEL
SHUTOFF, PTO SAFETY, GLOW PLUG
LAMP, FLASHER CUTOFF, PARK BRAKE
INTERFACE, FRONT WORKLIGHTS, AND
HVAC RELAYS
Replacement
terminal 3 and the other test probe to terminal 4.
replaced.
55-33
4. If the previous test showed continuity, touch one
ohmmeter probe to terminal 1 and the remaining
read approximately 79.5 ohms. If the reading is
not as specified, the relay is defective and needs
replaced.
20004391
58
energize.
replaced. 59
TESTING
HEADLIGHT, NEUTRAL START, AND CAB
POWER RELAYS
Replacement
terminal 87A and the other test probe to terminal
30.
continuity, the relay is defective and needs 60
replaced.
55-34
4. Repeat the previous test for terminal 30 and 87.
There should be no continuity between these
terminals. If tests indicate continuity, the relay is
energize.
probe to terminal 87. 61
replaced.
8. While the 12-volt power source is still connected,
touch an ohmmeter test probe to terminal 30 and
terminal 87A. There should be high resistance
indicating no continuity between the terminals. If
there is continuity, the relay is defective and
needs replaced.
62
55-35
GLOW PLUG POWER RELAY

Testing
1. Remove the glow plug power relay from the
tractor.
terminal 87 and the other test probe to terminal
30.
3. Observe the ohmmeter. There should be high
resistance between these terminals, indicating
no continuity. If tests indicate continuity, the relay
is defective and needs replaced. 30004023
63
energize.
replaced. 64
Installation (All Relays)

trying to install top panel. 1
5. Install the side panels, 3, and secure with the two 3 2
3
66064539
65
55-36
DIODES
There are three separate diodes used on cab
tractors.
1. Diode module, 1, used for HST “High” range
2. HST cruise control diode, 2, (6 Amp)
NOTE: The diode module, 1, is located underneath

the steering column console right side panel and the
HST cruise diode, 2 is centrally located underneath
the panels .
1
86064525
66
3. Rear PTO stationary operation diode, 3, (6 Amp)
Located in front of the hydraulic lift cover (HPL),
underneath cab platform. Diode is tied to wire 3
harness that is on top of transmission cover.
NOTE: Figure is shown, with left rear tire removed

from tractor for clarity.
Diodes are electrical devices which current is

allowed to pass in one direction, directing current
within a circuit. Diodes allow the use of one wire
within multiple circuits to control current flow to
electrical components, such as relays. The (DA) 86064529
model tractors utilize four diodes to direct current. 67
Two of these diodes are paired together in one case,
referred to as a diode module.
55-37
Module Testing
1. Remove the diode module suspected of being
faulty from the tractor.
NOTE: For this test, an electrical multimeter with
diode test capabilities may be used in place of an
ohmmeter. If a multimeter with diode testing
capabilities is unavailable, use an ohmmeter to test
as described below.

test probe to diode terminal “1”. Touch the black,
negative (−), ohmmeter test probe to diode
terminal “2”. Observe the ohmmeter.
flowing through the diode in that direction. If there
is continuity. Check to see that the test probes
are on the correct terminals, and if they are, the
diode module is defective and needs replaced.
30004050
68
4. If the previous test indicated the diode was
functioning properly, touch the red, positive (+),
ohmmeter test probe to terminal “2” of the diode
and the black, negative (--), test probe to terminal
“1” of the diode.
show little or no resistance, indicating continuity
in that direction. If the ohmmeter does not show
continuity, the diode module is defective and
needs replaced.
30004051
69
55-38
6. Repeat the test outlined in steps 2 through 5, to
test terminals 3 and 4 of the diode module.
Replace the diode module if test determine the
diode module to be defective. The diode should
show continuity only when red, positive (+),
positive test probe is touching terminal 4 and the
black negative (--) test probe is touching terminal
3.
20002218
70
Diode Testing
Use an ohmmeter to test the diodes.
Connect the ohmmeter leads to the diode terminals

and observe the meter reading, then reverse the
ohmmeter leads and observe the meter reading.
• Continuity should exist in one direction only.
If there is continuity in both directions, or if there is no

continuity in either direction, replace the faulty diode.
Power should flow in a positive to negative direction.
71
55-39
OPERATOR SAFETY MODULE

The operator safety module, 1, is part of the tractor
safe operation circuit. When the operator safety 1
module is energized it allows the ground circuit for
the control portion of the fuel shutoff solenoid relay to
be completed. If current no longer flows to the
operator safety module, the ground circuit for the
relay becomes open. This causes the fuel shutoff
solenoid relay to become non-energized. When the
relay becomes non-energized, the current to the fuel
shutoff solenoid is discontinued, stopping the tractor
engine. Current is supplied to the operator safety
module when the operator is seated, or when the
PTO is disengaged and the parking brake is applied. 86064528
The operator safety module, 1, is located under the
left steering wheel console panel. 72
Removal
left side panel from the tractor.
3. Unplug the wire harness connector from the 1
operator safety module.
4. Remove retaining screw and remove module
from tractor. 2
66064539
73
55-40
Testing
test probe to module terminal “B”. Touch the
black, negative (−), ohmmeter test probe to diode
terminal “C”. Observe the ohmmeter.
flowing through the operator safety module. If
there is continuity. Check to see that the test
probes are on the correct terminals, and if they
are, the operator safety module is defective and
needs replaced. 30004053
74
3. If the previous test indicated the operator safety
module was functioning properly, clamp the red,
positive (+), ohmmeter test probe to terminal “B”
of the safety module and the black, negative (−),
test probe to terminal “C” of the Safety module.
CAUTION
Only apply battery current to the operator safety
control module for 3--5 seconds or damage will
occur.
4. Connect a jumper wire from terminal “E” on the

operator safety module to the positive (+) 30004048
terminal of a 12-volt power supply. 75
5. Connect a jumper wire to terminal “B”.
6. While observing the ohmmeter, touch the jumper
wire to terminal “B’ from the negative (--) terminal
of the 12-volt power supply. There should be little
or no resistance, indicating continuity. If the
reading shows high resistance, the operator
safety module is defective and needs replaced.
Installation
1. Install module to support bracket with retaining
screw.
2. Connect the wire harness connector to the
operator safety module.
3. Install left side panel using four retaining screws.
negative (--) battery terminal
55-41
PARK BRAKE SAFETY ALARM (BUZZER)

1
The park brake safety alarm, 1, is located behind the
instrument panel. The buzzer will alarm for
approximately eight seconds, warning the operator
when an unsafe condition occurs.
For example:
• The buzzer will alarm, with the key in the “OFF”

position and the park brake disengaged.
• The buzzer will alarm, with the key in the “ON”
position, with the rear PTO engaged and the park
brake either engaged or disengaged. 86064525
76
Removal
the battery negative (--) terminal.
2. Remove the instrument panel from the dash
panel.
3. Disconnect the alarm, 1, from the tractor wire
harness.
Testing
NOTE: The alarm cannot be tested with an
ohmmeter.
Condition #1
Key “OFF”
Park Brake “OFF”
Alarm “ON”
1. Connect terminal #1 to the positive (+) terminal

of a 12 volt battery.
2. Connect terminal #5 to the negative (--) terminal
3. Install a switch between terminal #2 and negative
(--) terminal of the battery.
4. When the switch is closed the alarm should be
“OFF”. 60054385
5. When the switch is open the alarm should be 77

“ON”.
55-42
Condition #2
Key “ON”
Park Brake “OFF”
Operator Out of Seat
Alarm “ON”

of the battery.
4. Install a switch (seat switch) between terminal #3
and positive (+) terminal of the battery.
5. Install a switch (park brake) between terminal #2
and negative (--) terminal of the battery.
60054386
6. When both seat and park brake switches are
open the alarm should be “ON”. 78
Condition #3
Key “ON”
Park Brake “OFF” or “ON”
Operator Out of Seat
Rear PTO “ON”
Alarm “ON”

of the battery.
4. Install a switch (seat switch) between terminal #3
and positive (+) terminal of the battery.
5. Install a switch (park brake) between terminal #2
and negative (--) terminal of the battery. 60054387
6. Install a switch (rear PTO) between terminal #7 79

and positive (+) terminal of battery.
7. Open both seat and park brake switches.
8. Close rear PTO switch between terminal #7 and
positive (+) battery terminal.
9. With the seat and park brake switches open and
rear PTO switch closed the alarm should be
“ON”.
NOTE: If any of the above tests do not perform with
the expected results, replace the alarm.
55-43
Installation
1
1. Connect alarm, 1, to the tractor wire harness.
2. Install the instrument panel into the dash panel.
battery negative (--) terminal.
86064525
80
GLOW PLUG TIMER
The glow plug timer, 1, is an electronic timer that is
located under the top steering wheel console panel.
The timer controls how long the glow plugs and the
indicator light on the instrument panel remain
supplied with current when the key switch is turned
form the “OFF” position to the “ACC/RUN” position.
The glow plug timer delays the glow plugs and
indicator light on deluxe model tractors for 4-5
seconds and for 10-11 seconds on the economy
model tractors. The glow plug timer controls the glow
plug and indicator light circuit by supplying or cutting 1
the ground path to the glow plug power relay’s coil
circuit.
86064525
81
Removal
panel. 2 3
7. Unplug the connector from the glow plug timer 2
relay. 66064539
82
55-44
Testing
the battery.
2. Remove the bolt retaining the light timer to the
tractor and disconnect the timer from the main
wiring harness.
NOTE: The terminals are not number or letter coded
on the light timer. 1
2
3. Connect a jumper wire from terminal “C” on the
timer, 1, to the positive (+) terminal of a 12-volt
power supply.
4. Connect a test light, 2, from terminal “A” of the
timer, 1, to the positive (+) terminal of a 12-volt -- +
C
power supply. A
D
B
E
12 VOLTS
5. Connect a jumper wire from terminal “D” of the

timer, 1, to the negative (--) terminal of the 12-volt
power supply. Observe the test light, 2. 20000874
6. The test light should illuminate for approximately 83

4 – 5 seconds for the deluxe models and 10-11
seconds for economy models, then turn off. If the
test light fails to illuminate or does not turn off
after the specified time, the timer is defective and
needs replaced.
battery.
Installation
1. Plug the connector into the glow plug timer relay. 2
trying to install top panel.
4
5. Install instrument panel into top console panel. 3 2
4
4
3
66064539
84
55-45
Op. 55 201
1
ENGINE GLOW PLUGS
The engine glow plugs, 1, are located on the right
side of the engine cylinder head, above the fuel
injectors. The glow plugs are used to preheat the air
in the pre-combustion chamber. This aids in the
starting of the engine when cold.
50036021
85
The glow plugs utilize a heating element that is
contained in a stainless steel sheath, 1. The coiled
heating wire, 2, is sintered into magnesium oxide 1 2
powder, 3. The magnesium oxide powder is used to 4
evenly transfer heat to the stainless steel sheath,
which heats the air in the combustion chamber. The
magnesium oxide powder is also used to insulate the
heating wire from the outer sheath and glow plug
body.
The glow plug heats when electrical current is 3

passed from the glow plug electrode, 4, to one end
of the heating wire, 2. Electrical resistance warms the
heating wire when electrical current is flowing
through the wire. The opposite end of the wire is 86
connected to the sheath. The sheath and glow plug
body, 5, are grounded by the engine block.
NOTE: All DX tractors utilize a fast heating type glow

plug (marked Y-701RS).
Removal
the battery.
2. Remove the electrode nuts, 1, the electrical
connector, 2, and washers securing the 1
electrode bus bar, 3, to the glow plugs.
3. Remove the glow plug(s) from the engine
cylinder head.
10000896
87
55-46
Testing
1. Remove carbon from the sheath end of the glow
plug
NOTE: Do not test resistance using the glow plug
sheath.
glow plug electrode, 1. Touch the other test probe
to the glow plug body, 2.
3. Observe the ohmmeter reading, a resistance
reading of 0.8 ohms maximum is normal for the
DX model tractor glow plugs. If the resistance is
too high, the glow plug is defective and needs
replaced. 1 2
20000876
88
Installation
1. Thread the glow plugs into the engine cylinder 2
head. Torque each glow plug to 10 -- 15 N⋅m (11.0
-- 14.5 ft-lb).
2. Install the electrode bus, 1, and the washers onto
the glow plugs. Secure with the three (3) nuts, 2.
1
3. Connect the electrical connector, 3, to the wire
harness.
battery.
10000896
89
55-47
HAZARD FLASHER/TURN SIGNAL

CONTROL MODULE
The hazard flasher/turn signal control module, 1, is 1
located underneath the steering column top console
panel. The control module controls current flowing to
the hazard flasher/turn signal lights on the rear
fenders. Refer to the chart below for the functions of
the control module.
86064525
90
HAZARD/TURN SIGNAL RESULT

SWITCH POSITION
Hazard switch “On” Both flashers blink in unison.
Left turn signal “On” Left flasher and taillight blink and right flasher and taillight
remain solid.
Right turn signal “On” Right flasher and taillight blink and left flasher and taillight
remain solid.
Removal
panel. 2 3
7. Unplug the connector from the hazard flasher 2
module. 66064539
91
55-48
Testing 2. Connect a jumper wire to terminal 4 of the control
Use a 12 volt power source, a suitable switch, jumper module and to the positive (+) terminal of a test
wires and test lights to perform the 3 tests on the light. This test light will simulate the right flasher.
hazard flasher /turn signal control module. Connect the negative (--) terminal of the test light
to the negative (--) terminal of the power source.
NOTE: Disregard terminal markings on the module. 3. Connect a jumper wire to the positive (+) terminal
Refer to terminal markings in the illustration. of the power source and the switch.
Test 1 – Test 1 is used to verify that the control 4. Connect a jumper wire to the switch and terminal
module is supplying power to both of the hazard 2 on the control module.
lights. This test simulates the hazard switch being 5. Connect a jumper wire to the positive (+) terminal
turned to the “On” position. of the power source and to terminal 1 of the
control module.
1. Connect a jumper wire to terminal 3 of the control
module and to the positive (+) terminal of a test 6. Connect a jumper wire to the negative (--)
light. This test light will simulate the left flasher. terminal of the power source and to terminal 6 of
Connect the negative (--) terminal of test light to the control module.
the negative (--) terminal of the power source. 7. Move the switch to the “On” position, observe the
two test lights. Both should flash on and off
simultaneously.
20023430
92
55-49
module is functioning properly when the left turn module and to the positive (+) terminal of a test
switch being turned to the “Left” position. (amber). Connect a jumper wire to the (--)
module and to the positive (+) terminal of a test the two test lights. The left flasher and the left
light. This test light will simulate the right flasher taillight should both flash on and off while the
(amber). Connect a jumper wire to the (--) right flasher and right taillight remain lit (solid).
20023431
93
55-50
module is functioning properly when the right turn module and to the positive (+) terminal of a test
switch being turned to the “Right” position. (amber). Connect a jumper wire to the (--)
module and to the positive (+) terminal of a test the two test lights. The right flasher and the right
light. This test light will simulate the right flasher taillight should both flash on and off while the left
(amber). Connect a jumper wire to the (--) flasher and left taillight remain lit (solid).
20023432
94
55-51
Installation
1. Plug the connector into the hazard flasher 1
module, 1.
2. Tilt steering column fully rear rearward, before
trying to install top panel.
86064525
side and middle retaining screws, 5. 95
3
2
4 3
5
5
4
66064539
96
55-52
Op. 55 410
FUEL LEVEL SENDING UNIT 1

The fuel level sending unit, 1, is mounted on top of the
fuel tank and extends into the tank. The sending unit
utilizes a float the raise and lowers with the fuel level
inside the tank. The float regulates a variable
resistance to ground, which translates into move-
ment of the fuel gauge on the instrument panel. As
the float lowers (fuel being consumed) inside the
tank, the ground resistance increases, indicating
less fuel on the fuel gauge.
30002209
97
Removal
the battery.
2. Remove the fuel tank from rear of the tractor.
3. Disconnect the fuel level sending unit from the
wiring harness.
4. Remove the two screws, 1, to remove the fuel
level sending unit cover, 2.
1
2
30002210
98
5. Remove the five (5) retaining screws, 1, that
secure the sending unit, 2, to the fuel tank.
1
10043896
99
55-53
6. Carefully remove the sending unit, 1, from the
fuel tank.
1
7. Remove and discard the sealing gasket, 2, from
the sending unit, 1.
30002211
100
Testing
terminal “A” of the sending unit, touch the other
test probe to terminal “B” of the sending unit.
Observe the reading on the ohmmeter.
2. With the sending unit float in the down position
(tank empty), the ohmmeter should indicate
between 248--252 ohms. If the ohmmeter
reading is not within these specifications, the
sending unit is defective and needs replaced.
30004010
101
3. With the sender in the up position (tank full), the
ohmmeter should indicate between 28--32 ohms.
If the ohmmeter reading is not within these
specifications, the sending unit is defective and
needs replaced.
30004011
102
55-54
Installation
1. Install a new sealing gasket, 2, between the 1
sending unit, 1, and the fuel tank.
2. Carefully place the sending unit, 1, into the fuel
tank.
30002211
103
3. Secure the sending unit, 2, to the fuel tank using
the five (5) retaining screws, 1.
1
10043896
104
4. Install the fuel level sending unit cover, 2, using
the two screws, 1.
1
5. Connect the fuel level sending unit to the wiring 2
harness.
6. Reinstall fuel tank onto tractor.
battery.
30002210
105
55-55

The fuel shutoff solenoid, 1, is located on the right
side of the engine, threaded into the rear of the fuel
injection pump, 2. The fuel shutoff solenoid contains
a spring-loaded plunger that pushes the injection 1
pump control rack to the closed (shut-off) position
when the solenoid is not energized. When the key
switch is turned to the “ACC/RUN” or “START”
position, the safety stop relay closes completing the
circuit that energizes the solenoid. This retracts the 2
plunger from the injection pump, and the injection
pump control rack moves into the position that allows
the engine to start.
56064538
Removal
106
the battery.
2. Disconnect the wiring harness lead from the fuel
3. Using a pair of pliers, carefully remove the fuel
shutoff solenoid, 1, from the fuel injection pump,
2.
4. Remove and discard the sealing washer, 1,
which seals the solenoid, 2, to the fuel injection
pump.
20000885
107
Testing
1. Using a suitable measuring device, measure the 1
actuating pin, 1, protrusion distance, “A”, on the
25.5 -- 26.4 mm (1.004 -- 1.040 in.). If the distance
is not within these specifications, the solenoid is
108
55-56
NOTE: When connecting the 12-volt power supply to
the solenoid body, be sure paint is the removed from 3
the body. Otherwise, the power will not be transferred
to the solenoid.
2. Use jumper wires to connect the positive (+)

terminal of a 12-volt power supply to the solenoid
lead, 1. Connect the negative terminal of the 1
12-volt power supply to the solenoid body, 2. The
plunger should retract into the solenoid body. 2
3. Using a suitable measuring device, measure the
actuating pin, 1, protrusion distance, “B” on the
11.5 --14.5 mm (0.453 -- 0.571 in.). If the distance 109
is not within these specifications or the plunger
does not retract, the solenoid is defective and
needs replaced.
Installation
1. Install a new sealing washer, 1, on the solenoid,
2.
1
20000885
110
2. Thread the fuel shutoff solenoid, 1, into the fuel
injection pump, 2. Use pliers to tighten the
solenoid into the injection pump.
1
3. Connect the wiring harness lead, 3, into the fuel
4. Connect the negative (--) battery cable to the 3
battery.
2
56064538
111
55-57
Op. 55 414
1
ENGINE OIL PRESSURE SWITCH
The oil pressure sender, 1, is located on the top front
side of the engine. The switch opens under normal oil
pressure (above 6 psi) and closes when oil pressure
is low (below 6 psi) to complete the ground circuit of
the oil pressure warning light.
When the ground circuit is completed, the oil pressure

warning light illuminates on the instrument panel
when the key switch is turned to the “ON” position and
goes out when the engine is started. If the light does
not go out after the engine has started, first check the
engine oil level. If oil level is correct, check for a 112
malfunctioning sender or engine oil pump.
Testing
pressure switch terminal, 1, and the other test
lead to the switch body, 2. 3
no resistance, indicating continuity in the switch.
If there is no continuity, the switch is defective
and needs replaced.
NOTE: The following test is not a calibrated test. The
purpose of the test is to see if the switch opens at
pressure. 2
20000880
1. While the test leads are connected to the switch,
pressurize the switch oil pressure port, 3, with 113
low pressure (10-30 psi) compressed air.
2. Observe the ohmmeter. While air pressure is
being supplied to the oil pressure port, the
ohmmeter should indicate high resistance, or no
continuity. If there is continuity, the switch is
CAUTION
Do not use high pressure compressed air for the
following test, otherwise damage may occur to
the oil pressure switch.
55-58
ENGINE COOLANT TEMPERATURE

SENDING UNIT
The coolant temperature sender, 1, is located at the
left front side of the engine inside the thermostat 1
housing. This sender regulates a variable resistance
to ground, which translates into the movement of the
temperature gauge.
86064536
114
Testing
WARNING
Do not perform sending unit test with tractor
engine running. Contact with moving parts will
cause bodily injury.
NOTE: Engine paint must be removed from sending

unit body or the ohmmeter will indicate a false
reading when the ohmmeter test lead is touched to
sending unit body.
1. Disconnect the main wiring harness terminal, 2,
from the coolant temperature sending unit.
86064536
115
55-59
sending unit terminal, 1. Touch the other test lead 1
to the sending unit body, 2.
∞ 0
116
3. Observe the ohmmeter for resistance readings Coolant Temperature Sending Unit Temperature
at different engine operating temperatures. If
resistance is too high, the sending unit us 35° C (95° F) 670.0 ± 80 ohms
defective and needs replaced. 80° C (176° F) 118.0 ± 6 ohms
105° C (221° F) 54.5 ± 2.7 ohms
115° C (239° F) 42.0 ± 2.5 ohms
55-60
HI/LOW TRANSMISSION RANGE SWITCH

(HST)
The transmission range control switch, 1, is a
two-way momentary switch located on the right 1
control pod on the tractor. This switch changes the
hydraulic range of the transmission hydraulic pump.
The switch contains two bulbs that illuminate,
indicating what hydraulic range the transmission
hydraulic pump is in, “HI” (rabbit) or “LOW” (turtle).
When the switch is pushed to the “HI” range, current
is supplied to the transmission range solenoid, which
changes the position of the swash plate in the
hydraulic pump, increasing hydraulic oil flow. The
solenoid is not energized in the “LOW” position and
the transmission pump operates at normal hydraulic 10998318
oil flow. The “LOW” transmission setting is the default
setting, meaning the tractor will reset to the “LOW” 117
position when the tractor engine is shut off and
restarted.
The tractors may also be equipped with an optional
joystick switch, 1, that is mounted on the optional 1
two-spool remote valve.
10998370
118
Testing
1
1. Carefully pry the range switch, 1, from the right
control pod.
2. Disconnect the tractor wiring harness from the
switch.
10998318
119
55-61
terminal 9. Touch the other test probe to terminal
10.
4. Observe the ohmmeter. There should be
approximately 19.0 ohms of resistance between
the terminals. If resistance is high or off scale, the
“LOW” indicator light is faulty and the switch
needs replaced.
30004025
120
5. Repeat the test for terminals 7 and 8 for the “HI”
range indicator light. Replace the switch if test
results are not within the limit specified.
30004026
121
6. Hold the switch to the “LOW” (turtle) position.
Touch one ohmmeter test probe to terminal 2.
Touch the remaining ohmmeter test probe to
terminal 1.
and needs replaced.
30004027
122
55-62
8. Hold the switch in the “HI” (rabbit) position. Touch
one ohmmeter test probe to terminal 2. Touch the
other ohmmeter test probe to terminal 3.
and needs replaced.
10. If the switch is good, connect the wiring harness
to the switch and push the switch back into the
tractor control pod.
30004028
123
Optional Joystick Switch Testing
1. Disconnect the range switch connector, 1, from
the wiring harness. Remove the two (2) screws, 2,
2
retaining the switch to the front remote valve 1
joystick.
20003787
124
terminal “C”. Connect the other test probe to
A B
terminal “A”.
needs replaced. C
4. Press the “LOW” (turtle) button and observe the
replaced.
125
55-63
terminal “C”. Connect the other test probe to A
terminal “B”.
6. Press the “LOW” (turtle) button and observe the B
C
needs replaced.
replaced.
126
8. To replace the switch, remove the joystick cover
retaining screw, 1, then pull the switch out.
1
10998370
127
HI/LOW TRANSMISSION RANGE SOLENOID

(HST)
Deluxe model DX series tractors are all equipped
with a dual, “HI/LOW” range hydrostatic transmission
(HST). The transmission utilizes an electronic
transmission range solenoid, 1, to change the swash
plate angle within the transmission hydraulic oil
pump to “HI” range. This increases hydraulic oil flow
through the transmission. When the transmission is
in “LOW” range the solenoid is not energized and the
solenoid retracts, allowing the swash plate to return
to normal operating angle, reducing hydraulic oil flow
in the transmission. The transmission range solenoid
is located in a housing on the left side of the
transmission housing. 30002884 1
128
55-64
Removal
the battery.
NOTE: When removing the solenoid valve body from
the transmission, be sure not to lose the three (3)
O-rings, 1, that are located in the solenoid valve body
and the transmission case adapter block
1
30002887
129
2. Disconnect the solenoid leads, 3, from the tractor
wiring harness.
3. Remove the four (4) 5 mm hex head mounting
bolts, 1, securing the solenoid valve body, 2, to
the transmission housing. Remove the solenoid
valve body from the transmission adapter block.
2 3
30002884 1 1
130
Testing
2
1. Remove the solenoid assembly, 1, from the
solenoid valve body, 2. Be sure not to lose any
parts.
1
30002889
131
55-65
2. Connect an ohmmeter test lead to each of the
solenoid terminals.
indicate a resistance of approximately 7.5 -- 10.5
ohms.
4. If the reading is not within this specification, the
solenoid is defective and needs replaced.
30000740
132
5. Connect a positive (+) lead from a 12-volt power
source to one of the solenoid terminals, 1.
1
6. Connect the negative (--) lead from the 12-volt
power source to the remaining solenoid terminal.
7. Observe the solenoid. The solenoid plunger, 2,
should extend when voltage is applied. If the
plunger does not extend, the solenoid is
defective and need replaced. 2
8. Disconnect the 12-volt power source from the
solenoid. The plunger should retract immediate-
ly. If the plunger does not retract, the solenoid is
9. If the solenoid is good, install the solenoid 133

assembly back into the solenoid valve body.
Installation
1. Install the solenoid valve assembly, 1, to the 1
transmission adapter plate and secure with the
four (4) 5 mm hex head bolts, 2.
2. Connect the solenoid leads, 3, to the tractor
wiring harness.
battery.
2 2 3
30002884
134
55-66
ELECTRIC CRUISE CONTROL SWITCH

1
(HST)
The electric cruise control switch, 1, is located on the
right control pod . The cruise control switch controls
current to cruise control magnet. Cruise control is
used to maintain the tractor at a constant speed
forward or backward. When the cruise control switch
is pushed from the “OFF” position to the “SET”
position, the control circuit of the cruise control relay
is energized. This closes (completes) the function
circuit of the relay, which supplies power to the cruise
control magnet. When the cruise control switch is
released from the “ON” position, the switch rockers 10998318
to the “ON” position, which keeps the cruise control 135
activated until the switch is pushed to the “OFF”
position or the brake pedal or hand brake is engaged.
Current to the cruise control relay is interrupted when
either brake is engaged, which deactivates the cruise
control magnet. The cruise control switch is
equipped with an indicator light that will illuminate
when the switch is moved to the “SET” and “ON”
position, indicating the cruise control has been
activated.
Removal
the battery.
2. Carefully pry the switch from the control pod.
3. Disconnect the electric cruise control switch from
the wiring harness.
55-67
136
Testing placed in any of its three positions). The reading
Remove the switch from the wiring harness. should be between 55 ohms and 60 ohms.
NOTE: The switch terminals are identified on the NOTE: The light is not serviced separately. If it does
back of the switch. Numbers 1 and 4 are blank. not illuminate, replace the switch.
Using an ohmmeter, depress the switch to the “SET” Replace the switch if the correct readings are not
position and connect the ohmmeter leads across obtained during testing.
terminals 5 and 6, then across terminals 2 and 3. If
continuity exists across these terminals, the switch is Installation
operating properly. 1. Connect the electric cruise control switch to the
wiring harness.
Next place the switch in the “ON” (middle) position
and connect the ohmmeter leads across terminals 2 2. Push the cruise control switch, 1, into the right
and 3. If there is continuity, the switch is good. control pod.
To test the internal light bulb, connect the ohmmeter

leads across terminals 7 and 8 (the switch may be
55-68
CRUISE CONTROL MAGNET (HST)

The cruise control magnet, 1, is located under the
right cab platform and is attached to the hydrostatic 3 4
transmission (HST) linkage. The cruise control
magnet is a simple electromagnet. When the cruise
control switch is activated, current is supplied to the
cruise control magnet and the magnet locks the HST
control linkage in place. This maintains a constant
transmission speed, which translates to a constant
tractor ground speed, forward or reverse.
Removal
2 1
30003789
the battery.
2. Disconnect the main wiring harness connector, 137
2, from the cruise control magnet, 1.
3. Remove the two bolts, 3, which secure the cruise
control magnet mounting bracket, 4, to the
transmission. Remove the magnet from the
tractor.
55-69
Testing
Use an ohmmeter to test the cruise control magnet. ∞ 0
1. Disconnect the magnet from the tractor wiring

harness and connect the ohmmeter leads to the
two leads coming from the magnet.
• A meter reading of 11-12 ohms is normal.
138
2. Disconnect the ohmmeter from the magnet and
apply 12 volts across the magnet leads.
• The surface will become magnetized and
attract any ferrous object if the cruise control
magnet is working properly.
- +
If test results are not as outlined above, replace the
cruise control magnet.
139
Installation
3 4
1. Install the cruise control magnet, 1, and mounting
bracket, 4, to the tractor transmission and secure
the mounting bracket, 4, to the transmission
using the two bolts, 3.
2. Connect the main wiring harness connector, 2, to
the cruise control magnet.
battery.
2 1
20003789
140
55-70
CRUISE CONTROL BRAKE RELEASE

SWITCH (HST)
The HST cruise control brake release switch, 1, is a
push button type switch located on the brake pedals
upper support bracket. The switch is normally 1
retracted (inward), which completes the ground
circuit for the cruise control.
When both brake pedals are applied, the actuator

button is extended and the switch contacts are
opened, interrupting the ground circuit for the cruise
control allowing the cruise control to become
deactivated. 86064527
141
Removal
2. Remove the left steering column cowling, 1, by
removing the four retaining screws, 2.
3. Disconnect the wire harness from the switch.
2
4. Rotate switch counterclockwise to remove from
the support bracket.
66064539
142
Testing
Use an ohmmeter to test terminals of the switch for
continuity.
Extended Position
1. With the switch in the “extended” (brake ON)
position, continuity should not exist between the
terminals. If continuity exists in the “extended”
replaced.
Retracted Position
19985091
1. With the switch in the “retracted” (brake OFF)
position, continuity should exist between the 143
terminals. If continuity does not exist in the
needs replaced.
55-71
Installation
1. Thread the switch into the support bracket until
the actuator button is totally exposed on the
bottom side of the bracket.
2. Connect the wire harness to the switch.
3. Install the left steering column cowling, 1, with the
four retaining screws, 2. 2
1
66064539
144
55-72
CAB TO TRACTOR HARNESS MAIN

CONNECTORS 1
1. Power Connector (C2R – C2P)
(Circuits in Connector)
a. Unswitched Power (+)
b. Switched Power (+)
c. Glow Plugs
d. Headlights
e. Ground
2
2. Signal Connector (C3R – C3P) 10054350
145
(Circuits in Connector)
a. Switched Power (+)
b. Neutral Start
c. PTO Safety
d. Operator Presence
e. Park Brake
f. Alarm
g. Engine Temperature
h. Engine Oil Pressure
i. Horn
j. Fuel Level
k. Battery Charge Light
l. Tachometer
m. A/C Clutch
n. Front Work Lights
o. HST Cruise Control
p. Range shift (High/Low)
55-73
55-74
SECTION 55 - ELECTRICAL
Chapter 6 -- Schematics --
DX40--DX45 With Cab
CONTENTS

Electrical Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Start Circuit (Operator Present or Not Present) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safe Operation Operator Present Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Safe Operation Operator Not Present Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Safety Alarm Circuit (Key “Off” and Park Brake “Off”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Park Brake “On”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Park Brake “Off”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Headlights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cab Work Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Interior Cab Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Hazard Flasher Lights Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
HVAC Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Front and Rear Wiper Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Horn Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
HST Range “Low” Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
HST Range “High” Shift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
PTO Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Park Brake Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Engine Coolant Temperature Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Engine Low Oil Pressure Indicator Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Fuel Level Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Tachometer Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Beacon Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Radio Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
55-1
55-2
55-3
55-4
55-5
55-6
55-7
55-8
55-9
55-10
55-11
55-12
55-13
55-14
55-15
55-16
55-17
55-18
55-19
55-20
55-21
55-22
55-23
55-24
55-25
55-26
PAGE LEFT BLANK
55-27
SAFETY START CIRCUIT (OPERATOR PRESENT OR NOT PRESENT)
66064543
1
55-28
SAFETY START CIRCUIT (OPERATOR PRESENT OR NOT PRESENT)

NOTE: The safety start circuit is shown with:

• Rear PTO “OFF”
• Operator “IN” or “OUT” of seat
to:
switch terminals:

1. Current flows from the “A” terminal of the ignition switch to terminal #86 of the neutral start relay.

2. The #2, 10-amp fuse provides current to:

• Terminals 2:1 and 2:5 of Fuel shutoff relay
• Neutral start safety switch
• Main PTO switch

1. Range Neutral Switch – When the transmission range selector is placed in the neutral position, the switch
contacts close, allowing current to be sent to terminal #1 of the Mid PTO safety switch and terminal #30 of
the neutral start relay.
2. Main PTO Switch – With the main PTO switch in the “OFF” position :
• Terminals #2 and #4 are connected
Sending current to terminal #2 of the Mid PTO switch
3. Mid PTO Switch – With the Mid PTO in the “OFF” position:
Sending current to the engine run with stationary PTO diode
Sending current to terminal #1: 1 of the PTO safety start relay
4. Operator’s Seat Switch -- The operator’s seat switch does not have an affect on the starting circuit.
55-29
Engine Run with Stationary PTO Diode

1. The diode provides current to terminal #4 of the operator seat safety switch and terminal “E” of the operator
safety module.
Safety Module Operation

1. With current supplied to terminal “E” of the module, the module completes the ground path through terminals
“B” and “C” of the module. Terminal “B” of the module provides the ground path for the fuel shutoff relay.
Relay Functions
1. PTO Safety Start Relay – When current is supplied to terminal # 1:1 from the mid PTO safety switch and
a ground source is supplied to terminal #1:2 from the chassis ground, the relay is energized. When energized,
terminals #1:3 and 1:5 are latched. Terminal #1:5 completes the ground path for terminal #85 of the neutral
start relay.
2. Neutral Start Relay – When current is supplied to terminal #86 from terminal “A” of the ignition switch and
a ground source is supplied to terminal #85 from the PTO safety start relay, the relay is energized. When
energized, terminals # 30 and #87 are latched. Terminal #87 sends current to the starter motor, to rotate the
engine.
3. Fuel Shutoff Relay -- When current is supplied to terminal #2:1 from the #2 fuse and a ground source
supplied to terminal #2:2 from the operator safety module, the relay is energized. When energized, terminals
2:3 and 2:5 are latched. Terminal #2:3 supplies current to the fuel shutoff solenoid. When the solenoid is
energized, the solenoid plunger retracts and allows fuel to flow to the injection pump, allowing the engine to
start.
55-30
SAFETY START CIRCUIT TROUBLESHOOTING

Starter will not energize. Insufficient battery charge Recharge or replace battery
Blown 50-amp fuse Replace 50-amp fuse
Faulty ignition switch Check switch, replace if neces-

sary
Blown #2, 10-amp fuse Replace 10-amp fuse
Faulty neutral start safety switch Check switch, replace if neces-

sary
Faulty Mid PTO safety switch Check switch, replace if neces-

sary
Faulty Main PTO safety switch Check switch, replace if neces-

sary
Faulty engine run with stationary Check diode, replace if necessary

rear PTO diode
Faulty PTO safety start relay Check relay, replace if necessary
Faulty neutral safety start relay Check relay, replace if necessary
Faulty Starter motor Check starter, replace if neces-

sary
Starter will energize but engine Blown #2, 10-amp fuse Replace 10-amp fuse
will not start
Faulty operator safety module Check module, replace if neces-
sary
Faulty fuel shutoff relay Check relay, replace if necessary
Faulty fuel shutoff solenoid Check solenoid, replace if neces-

sary
55-31
SAFE OPERATION OPERATOR PRESENT CIRCUIT
66064544
55-32
SAFE OPERATION OPERATOR PRESENT CIRCUIT

to:
• Terminal #2 operator seat safety switch

1. Operator Seat Switch – When the operator is in the seat, the switch contacts are closed, allowing current
to flow through the switch to terminal “E” of the operator safety module.

1. With current supplied to terminal “E” of the operator safety module, by the operator seat switch, the module
completes the ground path through terminals “B” and “C” of the module. Terminal “B” of the module provides
the ground path for the fuel shutoff relay.
Fuel Shutoff Relay

1. When current is provided to fuel shutoff relay by the #2, 10-amp fuse and a ground circuit completed by the
operator safety module, the fuel shutoff relay is energized.
2. When the fuel shutoff relay is energized, terminals #2:5 and 2:3 are latched, providing current to the fuel
shutoff solenoid. When the solenoid is energized, the solenoid plunger retracts and allows the fuel to flow
to the fuel injection pump. This allows the engine to remain operating.
55-33

TROUBLESHOOTING

Tractor will not operate with oper- Blown #2, 10-amp fuse Replace 10 amp fuse
ator present.
Faulty operator seat safety switch Check switch, replace if neces-
sary

sary

sary
55-34
PAGE LEFT BLANK
55-35
SAFE OPERATION OPERATOR NOT PRESENT CIRCUIT
66064545
55-36
SAFE OPERATION OPERATOR NOT PRESENT CIRCUIT

• Operator NOT in the seat
to:
• Neutral start safety switch

1. Range Neutral Switch – When the transmission range selector is placed in the neutral position, the switch
contacts close, allowing current to be sent to terminal #1 of the Mid PTO safety switch.
2. Mid PTO Switch – With the Mid PTO in the “OFF” position, the switch contacts close, sending current to the
engine run with stationary PTO diode, the diode provides current to terminal #4 of the operator seat safety
switch and terminal “E” of the operator safety module.
3. Operator Seat Switch – When the operator is not in the seat, the switch contacts are open, not allowing
current to flow through the switch.

1. With current supplied to terminal “E” of the operator safety module, by the engine run with stationary PTO
diode, the module completes the ground path through terminals “B” and “C” of the module. Terminal “B” of
the module provides the ground path for the fuel shutoff relay.
Fuel Shutoff Relay
1. When current is provided to fuel shutoff relay by the #2, 10-amp fuse and a ground circuit completed by the
operator safety module, the fuel shutoff relay is energized.
2. When the fuel shutoff relay is energized, terminals #2:5 and 2:3 are latched, providing current to the fuel
shutoff solenoid. When the solenoid is energized, the solenoid plunger retracts and allows the fuel to flow
to the fuel injection pump. This allows the engine to remain operating.
55-37

TROUBLESHOOTING

Tractor will not operate without Blown #2, 10-amp fuse Replace 10 amp fuse
operator present.
Faulty Neutral Start safety switch Check switch, replace if neces-
sary
Faulty Mid PTO safety switch Check switch, replace if neces-

sary
Faulty engine run with stationary Check diode, replace if necessary

rear PTO diode

sary

sary
55-38
PAGE LEFT BLANK
55-39
SAFETY ALARM CIRCUIT (KEY “OFF” AND PARK BRAKE “OFF”)
66064558
55-40
SAFETY ALARM CIRCUIT (KEY “OFF” AND PARK BRAKE “OFF”)

2. From the starter motor, current flows through the 50-amp fuse to the #7 15-amp fuse.
3. The #7 15-amp fuse provides current to terminal “1” of the park brake alarm.
Park Brake Safety Switch
1. When the park brake is not applied the contacts of the switch are open. Without continuity through the switch
the ground path is disrupted and not providing a ground source for terminal “2” of the park brake alarm.
Park Brake Alarm
The park brake alarm will sound when the following terminals of the alarm are as follows:
• Terminal “1” has current supplied

• Terminal “2” does NOT have a ground source
• Terminal “5” has a ground source supplied
SAFETY ALARM CIRCUIT (KEY “OFF” AND PARK BRAKE “OFF”) TROUBLESHOOTING

Alarm will not sound Blown main 50-amp fuse Replace 50-amp main fuse
Park brake switch failed in closed Replace park brake switch
mode
Open circuit in harness to park Inspect wiring harness and repair as nec-
brake alarm essary
Defective park brake alarm Replace park brake alarm
Alarm will not shut off Park brake failed in open mode Replace park brake switch
Short circuit in harness to park Inspect wiring harness and repair as nec-
brake alarm essary
55-41
SAFETY ALARM CIRCUIT (KEY “ON”, REAR PTO “ON”, OPERATOR NOT PRESENT AND
PARK BRAKE “ON”)
66064561
55-42
PARK BRAKE “ON”)
• To the #7 15-amp fuse

#2, 10-amp Fuse
travels, through the #2, 10-amp fuse.
2. The 10-amp fuse supplies current to the main PTO safety switch.
#4, 10-amp Fuse

2. The 10-amp fuse supplies current to:
• Terminal “6” of the park brake alarm
#5, 7.5-amp Fuse

travels, through the #5, 7.5-amp fuse.
2. The 7.5-amp fuse supplies current to terminal #2 of the instrument panel.
#7, 15-amp Fuse

1. Provides current to terminal “1” of the park brake alarm.

1. Operator Seat Switch -- When the operator is not in the seat, the operator seat safety switch contacts are
open not allowing current flow through the switch.
2. Main PTO Switch -- When the main PTO selector is placed in the “ON” position terminals #1 and #3 are
connected, terminal #3 of the main PTO switch provides current to terminal #7 of the park brake alarm.
3. Park Brake Switch -- When the park brake is applied the switch contacts close connecting terminals #2 and
#4 also #1 and #3 of the switch. Terminal #3 provides a ground source to terminal “2” of the park brake alarm.
Relays Operation
1. PTO Safety Start Relay -- The PTO safety start relay is not energized, when the relay is not energized
terminals #1:3 and #1:4 are latched. Terminal #1:4 provides the ground source for terminal “12” of the
instrument panel. When instrument panel terminal “12” has a ground source and terminal “2” has current,
the PTO indicator light illuminates.
55-43
Park Brake Alarm


• Terminal “2” does have a ground source supplied
• Terminal “3” does NOT have current supplied
• Terminal “6” does have current supplied
PARK BRAKE “ON”) TROUBLESHOOTING

Park brake switch failed in open Replace park brake switch
mode
brake alarm essary
Operator seat safety switch failed in Replace seat switch
closed mode
brake alarm essary
55-44
PAGE LEFT BLANK
55-45
PARK BRAKE “OFF”)
66064559
55-46
PARK BRAKE “OFF”)
• To the #7 15-amp fuse

#2, 10-amp Fuse
2. The 10-amp fuse supplies current to the main PTO safety switch.
#4, 10-amp Fuse

• Terminal “6” of the park brake alarm
#5, 7.5-amp Fuse

travels, through the #5, 7.5-amp fuse.
2. The 7.5-amp fuse supplies current to terminal #2 of the instrument panel.
#7, 15-amp Fuse

1. Provides current to terminal “1” of the park brake alarm.

1. Operator Seat Switch -- When the operator is not in the seat, the operator seat safety switch contacts are
open not allowing current flow through the switch.
2. Main PTO Switch -- When the main PTO selector is placed in the “ON” position terminals #1 and #3 are
connected, terminal #3 of the main PTO switch provides current to terminal #7 of the park brake alarm.
3. Park Brake Switch -- When the park brake is not applied the switch contacts are open. Without continuity
through the switch the ground path is disrupted and not providing a ground source for terminal “2” of the park
brake alarm.
Relays Operation
1. PTO Safety Start Relay -- The PTO safety start relay is not energized, when the relay is not energized
terminals #1:3 and #1:4 are latched. Terminal #1:4 provides the ground source for terminal “12” of the
instrument panel. When instrument panel terminal “12” has a ground source and terminal “2” has current,
the PTO indicator light illuminates.
55-47
Park Brake Alarm


• Terminal “2” does NOT have a ground source supplied
• Terminal “3” does NOT have current supplied
PARK BRAKE “OFF”) TROUBLESHOOTING

Park brake switch failed in closed Replace park brake switch
mode
brake alarm essary
Operator seat safety switch failed in Replace seat switch
closed mode
brake alarm essary
55-48
PAGE LEFT BLANK
55-49
GLOW PLUG CIRCUIT
66064546
7
55-50
GLOW PLUG CIRCUIT

The engine glow plugs warm the engine pre-combustion chambers to assist in starting the engine in colder
temperatures.
The engine glow plug circuit is shown with :
• Ignition switch in the “ACC/RUN” position

• Glow plug indicator light illuminated
• Glow plugs activated
• Terminal #30 of the glow plug power relay
5. Current is supplied by the #1 fuse to terminal #86 of the glow plug power relay and terminal #4 of the glow
plug timer relay
Relay Functions
1. When the glow plug timer relay has current provided to terminal #4 and ground source to terminal #3, the
relay is activated, latching terminals #3 and #6.
2. Terminal #6 of the glow plug timer relay provides the ground source for terminal #85 of the glow plug power
relay. When ground source is provided to terminal #85, the glow plug power relay is activated, latching
terminals #30 and #87.
3. Terminal #87 of the glow plug power relay provides current to the glow plugs until the glow plug timer relay
cuts of the ground source to the glow plug power relay.
4. Terminal #87 also supplies current to terminal 4:1 of the glow plug lamp relay.
5. The glow plug lamp relay has a ground source provide to terminals 4:2 and 4:5 by the tractor main ground.
6. With current provide to terminal 4:1 and ground to terminal 4:2 the glow plug lamp relay is activated , latching
terminals 4:3 and 4:5. Terminal 4:3 provides the need ground source for terminal #7 of the instrument panels
and the glow plug indicator light illuminates. Terminal #2 of the instrument panel provides the current from
the # 5, 7.5-amp fuse. The glow plug indicator light will illuminate until, the glow plug timer relay cuts off the
ground source to the glow plug power relay which provides current to the glow plug lamp relay.
55-51
GLOW PLUG CIRCUIT

TROUBLESHOOTING

Engine glow plugs will not heat Insufficient battery charge Test battery. Charge, add water, or

necessary
Blown #1, 7.5-amp glow plug circuit Inspect fuse and replace as
fuse necessary

necessary
Corroded electrode buss bar Remove buss bar, clean bar and
connection glow plug electrodes
Defective glow plug(s) Test glow plug(s) and replace as

necessary
sary
Glow plug indicator light will not Insufficient battery charge Test battery. Charge, add water, or
illuminate while key switch is in replace as necessary
“ACC/RUN/HEAT” or “START”
position Blown 50-amp main fuse Inspect main fuse and replace as
necessary

necessary
sary
Faulty glow plug indicator bulb Check glow plug indicator light and
Defective glow plug indicator light Test timer and replace as neces-
timer sary
Glow plug indicator light circuit Check circuit connections,

open grounds, and wires
Defective glow plug lamp relay Test relay and replace as neces-
sary
Blown #5, 7.5-amp glow plug circuit Inspect and replace fuses as
or instrument panel fuse necessary
Glow plug indicator light remains Defective glow plug indicator light Test timer relay and replace as
illuminated after 5 seconds when timer relay necessary
keys switch is in “ACC/RUN”
position
Short circuit between the glow plug Check wiring between the instru-
indicator light and terminal “4:3” of ment panel and timer
the glow plug lamp relay.
55-52
PAGE LEFT BLANK
55-53
HEADLIGHTS CIRCUIT
66066099
55-54
HEADLIGHTS CIRCUIT (POSITION, LOW AND HIGH BEAMS)

to:
5. The 10-amp fuse supplies current to terminal # 2 of the headlights stalk switch and terminal 9:5 of the
headlight relay.
Position Lights Position

1. When the stalk switch is rotated to the first (Position Lights) position, current is transferred from terminal #2
to terminal #7.
2. Terminal #7 provides current to the following:
• Instrument panel illumination
• Cab interior opera light
• Right and left taillight
• License plate lights
3. Ground source for these lights is provided by the chassis ground.
Headlights Position
1. When the stalk switch is rotated to the second (Headlight) position, current is transferred from terminal #2
to terminal #6.
2. Terminal #6 provides current to terminal 9:4 of headlight relay. The headlight relay is not energized, terminals
9:4 and 9:3 are latched. Terminal 9:3 provides current to terminal “B” of headlights.
Headlights Relay
1. When a current is provided to terminal 9:1 and a ground source provided to terminal 9:2 the relay is energized.
The energized relay latches terminals 9:3 and 9:5. (Stalk switch pushed downwards.)
2. Terminal 9:5 is provided current from the #4, 10-amp fuse.
3. Terminal 9:3 provides current to:
• Front headlights, terminal “B”
55-55
HEADLIGHTS CIRCUIT TROUBLESHOOTING

Position lights will not illuminate Ignition switch not in the “ON” Place ignition switch in the “ON”
position position
Faulty stalk switch Check switch, replace if

necessary.
Faulty ground connection Check ground circuit, correct if

necessary
Faulty taillight bulb Replace bulb
Headlights will not illuminate Ignition switch not in the “ON” Place ignition switch in the “ON”
position position
Faulty stalk switch Check switch, replace if

necessary.
Faulty headlight relay Check relay, replace if

necessary.

necessary
Faulty headlight bulb Replace bulb
55-56
PAGE LEFT BLANK
55-57
CAB WORK LIGHTS CIRCUIT
66064513
55-58
CAB WORK LIGHTS CIRCUIT

to:
• To terminal # 30 of the cab power relay
5. The 7.5-amp fuse supplies current to terminal # 86 of the cab power relay.
Cab Power Relay

1. When a current is provided to terminal #86 and a ground source provided to terminal #85 the relay is
energized. The energized relay latches terminals #30 and #87.
2. Terminal #30 is provided current from the main fuse, 50-amp.
3. Terminal #87 provides current to:
• Fuse #27, 20-amp
4. The #27, 20-amp fuse, provides current to terminals #2 and #5 of the cab work lights switch.
Cab Work Lights Switch
(Front Lights)
1. When the switch is placed in the first (middle) position, current is transferred from terminal #2 to terminal #3.
2. Terminal #3 provides current to the two front cab work lights.
(Front and Rear Work Lights)

1. When the switch is placed in the second (upper) position, current is transferred from terminal #2 to terminal
#3 and terminal #5 to terminal #6
2. Terminal #3 provides current to the two front cab work lights and terminal #6 provides current to the rear cab
work lights.
55-59
CAB WORK LIGHTS CIRCUIT TROUBLESHOOTING

Cab work lights will not illuminate Ignition switch not in the “ON” Place ignition switch in the “ON”
position position
Blown #1, 7.5-amp fuse Replace 7.5-amp fuse
Faulty cab power relay Test relay, replace if necessary
Faulty cab work light switch Check switch, replace if

necessary.

necessary
Faulty light bulb Replace bulb
55-60
PAGE LEFT BLANK
55-61
INTERIOR CAB LIGHTS CIRCUIT
66064514
10
55-62
INTERIOR CAB LIGHTS CIRCUIT

to:
• To # 6, 15-amp fuse
3. The #6, 15-amp fuse provides current to the #22, 2-amp fuse, (upper cab fuse block).
4. The 2-amp fuse provides current to the dome light.
5. The dome light will illuminate if the following occur:
• Right door opened
• Left door opened
• Dome light switch placed in “ON” position.
These three actions provide a ground source for the dome light.
INTERIOR CAB LIGHTS CIRCUIT TOUBLESHOOTING

Dome light will not illuminate Blown #6, 15-amp fuse Replace 15-amp fuse
Faulty dome light switch Check dome light switch, replace

dome light assembly, if necessary.
Faulty dome light bulb Replace bulb
Dome light will not go out when Faulty door switch or misadjusted Test switches or adjust striker
doors are closed striker plate. plates to actuate switch when
doors are closed.
55-63
HAZARD FLASHER LIGHTS CIRCUIT
66064520
11
55-64
HAZARD FLASHER LIGHTS CIRCUIT

to:
• #6, 15-amp fuse
3. The #6, 15-amp fuse provides current to terminal #3 of the hazard switch.
Hazard Switch
1. When the hazard switch is placed in the “ON” position, current is transferred from terminal #3 to terminal #2.
2. Terminal #2 of the switch sends current to:
• Terminal #2 of the hazard/turn flasher module
• Terminal (5:4) of the flasher cutoff relay
3. An internal light will flash on and off to indicate hazard flashers are in the “ON” position.

1. The flasher relay is not energized, when not energized terminals (5:4) and (5:3) are latched.
2. Terminal (5:3) sends current to terminal #1 of the flasher module.
Hazard/Turn Flasher Module

1. With current being provide to terminals #1 and #2 and a ground source being provided to terminal #6, the
module sends out pulsating current from terminals #3 and #4.
2. Terminal #3 sends pulsating current to:
• Left hazard light
• Light in hazard switch
• Terminal #9 of instrument panel
3. Terminal #4 sends pulsating current to:

• Right hazard light
• Terminal #19 of instrument panel
55-65

TROUBLESHOOTING

Hazard Signal Lights will not Blown #6, 15-amp hazard signal Inspect fuse and replace as neces-
illuminate or flash fuse sary
Hazard signal bulb(s) burnt out Inspect bulb(s) and replace as

necessary
Defective hazard switch Test switch and replace as neces-

sary
Defective flasher cutoff relay Test flasher relay by using a known

functioning flasher relay and re-
place as necessary
Defective hazard/turn flasher Test module and replace as neces-

module sary

Instrument panel hazard indica- Indicator bulb(s) burnt out Inspect bulb and replace as neces-
tor(s) does not illuminate sary

55-66
PAGE LEFT BLANK
55-67
66064521
12
55-68

to:
• To #6, 15-amp fuse
• Terminal #3 of turn signal stalk switch
6. The #6, 15-amp fuse provides current to terminal (5:5) of the flasher cutoff relay.

1. When the #3, 10-amp fuse supplies current to terminal (5:1) and a ground source is supplied to terminal (5:2)
of the relay, the relay latches terminals (5:3) and (5:5).
2. Current from the #6, 15-amp fuse is transferred from terminal (5:5) to (5:3) of the relay.
3. Terminal (5:3) supplies current to terminal #1 of the flasher module.
Turn Signal Switch / Flasher Module

1. When the turn signal switch is place in the “RIGHT TURN” position, current is transferred from terminal #3
to terminal #9 of the switch.
2. When the following occur, the flasher module is energized:
• Terminal #7 of the flasher module is supplied with current
• Terminal #6 of the module is supplied with a ground source
3. When the flasher module is energized, the following terminal functions are:
• Terminal #3, left taillight continuous illumination
• Terminal #4, right taillight pulsating illumination
• Terminal #10, left hazard light continuous illumination
• Terminal #11, right hazard light pulsating illumination
Instrument Panel
1. Terminal #19 of the instrument panel is supplied pulsating current by terminal #4 of the flasher module.
2. Terminal #9 of the instrument panel is supplied continuous current by terminal #3 of the flasher module.
3. Terminal #24 is the ground source fro the instrument panel.
Ground Sources
1. The ground source for the flasher module, cutoff relay and instrument panel is the chassis ground located
at the engine starter mounting bolt.
55-69

TROUBLESHOOTING


sary
sary
Defective directional signal switch Test switch and replace as neces-

sary

ule sary


55-70
PAGE LEFT BLANK
55-71
66064522
13
55-72

to:
• To #6, 15-amp fuse
• Terminal #3 of turn signal stalk switch
6. The #6, 15-amp fuse provides current to terminal (5:5) of the flasher cutoff relay.

1. When the #3, 10-amp fuse supplies current to terminal (5:1) and a ground source is supplied to terminal (5:2)
of the relay, the relay latches terminals (5:3) and (5:5).
2. Current from the #6, 15-amp fuse is transferred from terminal (5:5) to (5:3) of the relay.
3. Terminal (5:3) supplies current to terminal #1 of the flasher module.
Turn Signal Switch / Flasher Module

1. When the turn signal switch is place in the “LEFT TURN” position, current is transferred from terminal #3 to
terminal #8 of the switch.
2. When the following occur, the flasher module is energized:
• Terminal #6 of the module is supplied with a ground source
3. When the flasher module is energized, the following terminal functions are:
• Terminal #3, left taillight pulsating illumination
• Terminal #4, right taillight continuous illumination
• Terminal #10, left hazard light pulsating illumination
• Terminal #11, right hazard light continuous illumination
Instrument Panel
1. Terminal #19 of the instrument panel is supplied continuous current by terminal #4 of the flasher module.
2. Terminal #9 of the instrument panel is supplied pulsating current by terminal #3 of the flasher module.
3. Terminal #24 is the ground source fro the instrument panel.
Ground Sources
1. The ground source for the flasher module, cutoff relay and instrument panel is the chassis ground located
at the engine starter mounting bolt.
55-73

TROUBLESHOOTING


sary
sary
Defective or directional signal Test switch and replace as neces-

switch sary

ule sary


55-74
PAGE LEFT BLANK
55-75
HVAC CIRCUIT
66064510
14
55-76
HVAC CIRCUIT
to:
• To Terminal # 30 of the cab power relay
5. The #1, 7.5-amp fuse provides current to terminal # 86 of the cab power relay.
Cab Power Relay

1. When current is provided to the cab power relay by fuse #1and the ground circuit is completed by the chassis
ground, the cab power relay is energized.
2. When the relay is energized, terminals # 30 and # 87 are latched, providing current to cab fuse # 24, 20- amp
fuse.
3. The #24, 20-amp fuse provides power to terminals 1-1 and 1-3 of the HVAC relay.
HVAC Relay
1. When current is provided to the HVAC relay by fuse #24 and the ground circuit is completed by the chassis
ground, the cab power relay is energized.
2. When the relay is energized, terminals 1-3 and 1-4 are latched, providing current to HVAC fan switch.
HVAC Fan Switch

1. When the HVAC fan switch is place in the “LOW” “MED” or “HIGH” speed positions, current is transferred
from terminal C-115 to C-118, C-117 and C-116 of the switch.
2. Terminal C-119 provides current to terminal #2 of the HVAC mode switch.
HVAC Mode Switch

1. When the HVAC mode switch is place in the “ON” position, current is transferred from terminal # 2 to terminal
#3.
2. Terminal #3 provides current to the thermostat switch.
HVAC Thermostat Switch

1. When the thermostat switch reads the correct temperature from the evaporator coils, the switch closes.
2. When the thermostat switch closes current is sent to the A/C low pressure switch.
High and Low A/C pressure Switches

1. When correct low side pressure is present at the A/C low pressure switch, the switch closes sending current
to the A/C high pressure switch. (Pressure Range of 4 to 20 psig)
2. When the correct high pressure is present at the A/C high pressure switch, the switch closes sending current
to A/C compressor clutch. (Pressure Range of 260 to 400 psig)
55-77
A/C Compressor Clutch
1. When current and proper ground is present at the A/C compressor clutch, the clutch locks and allows the
fan belt to drive the A/C Compressor.
HVAC FAN
1. Terminal C-118 provides current to the fan resister for low speed of the fan.
2. Terminal C-117 provides current for the fan resister for medium speed of the fan.
3. Terminal C-116 provides current for the fan resister for high speed of the fan.
4. The fan is provided a ground source by terminal “E” of the fan.
55-78
HVAC CIRCUIT
TROUBLESHOOTING

HVAC will not work Ignition switch not in the “ON” Place ignition switch in the “ON”
position position
Faulty HVAC relay Check relay, replace if necessary
Faulty HVAC mode switch Check switch, replace if neces-

sary
Faulty HVAC fan switch. Check switch, replace if neces-

sary
Faulty low pressure switch or A/C Check switch, replace if neces-

system press low side pressures sary or test pressures
too low. of A/C system
Faulty high pressure switch or A/C Check switch, replace if neces-

system press high side pressures sary or test pressures
excessive . of A/C system
Compressor clutch faulty Check clutch, replace if neces-

sary.
Fan speed incorrect or fan not Faulty HVAC fan switch. Check switch, replace if neces-
working sary
Faulty blower motor resistor Check resistor replace blower as-

sembly if necessary.
Faulty blower motor Check motor, replace if necessary
55-79
66064515
15
55-80

to:
• To terminal #30 of the cab power relay.
5. The 7.5-amp fuse supplies current to:
• Terminal #86 of the cab power relay
Cab Power Relay

• Fuse #25, 15-amp
4. The #25, 15-amp fuse, provides current to auxiliary power socket.
Ground Sources
1. The ground source is the chassis ground located at the engine starter mounting bolt.

TROUBLESHOOTING

Power socket does not have Ignition switch not in the “ON” Place ignition switch in the “ON”
Current present. position position
Power socket connection not Check connector for proper con-

making contact. tact.
Faulty power socket Check socket , replace if neces-

sary
55-81
FRONT AND REAR WIPER CIRCUIT
66064517
16
55-82
FRONT AND REAR WIPER CIRCUIT

to:
Cab Power Relay

• Fuse #26, 15-amp
4. The #26, 15-amp fuse, provides current to:

• Terminal #6 and #3 of the front wiper switch
• Terminal “B” of the rear wiper switch
• Terminal #1 of the front wiper motor
Front Wiper and Washer

1. Current is supplied to terminal #6 of the front wiper switch.
2. When the switch is place in the “ON” position the current is transferred from terminal #6 to terminal #7 of the
switch.
3. Terminal #7 supplies current to terminal #2 of the switch (switch indicator light) and terminal #2 of the front
wiper motor.
4. With current supplied to terminal #2 and ground source supplied to terminal #4 of the motor, the motor will
now rotate.
5. When switch terminal #2 has current and #8 has a ground source, the switch indicator light will illuminate.
6. When the switch is placed in the upper position, terminal #3 and terminal #5 are connected..
7. Terminal #5 of the switch provides current to terminal #1 of the front washer pump.
8. When pump terminal #1 has current and terminal #2 has a ground source. The pump will deliver fluid to the
front washer.
9. When the front wiper switch is placed in the “OFF” position, terminals #6 and #1 are connected.
10. Terminal #1 of the switch provides current to terminal #3 of the motor.
11. Terminal #1 of the motor (Park) and terminal #3 (Park Feed) have current present when, the front wiper switch
is placed in the “OFF” position. The “Park” function allows the motor to return to the “Home Position” no matter
what position the motor shaft was in when the switch is placed in the “OFF” position.
55-83
Rear Wiper and Washer
1. Rear wiper switch terminal “B” is supplied current from the #26, 15-amp fuse.
2. When the switch is place in the first position the rear wiper motor rotates.
3. When the switch is placed in the second position the rear wiper motor rotates and the rear pump is provided
current to terminal #1 and delivers fluid.
55-84
FRONT AND REAR WIPERS

TROUBLESHOOTING

Front wiper will not work Ignition switch not in the “ON” Place ignition switch in the “ON”
position position
Faulty wiper switch Check switch, replace if neces-

sary
Faulty wiper motor Check wiper motor , replace if

necessary
Rear wiper will not work Ignition switch not in the “ON” Place ignition switch in the “ON”
position position
Faulty wiper switch Check switch, replace

motor assembly if necessary
Faulty wiper motor Check wiper motor, replace as-

sembly if necessary.
55-85
HORN CIRCUIT
66064519
17
55-86
HORN CIRCUIT
to:
• #7, 15-amp fuse
3. The #7, 15-amp fuse provides current to terminal #1 of the turn signal/horn stalk switch.
Stalk Switch/Horn
1. When the stalk switch is pushed inwards, to activate the horn, terminals #1 and #4 are connected.
2. Terminal #4 supplies current to terminal #3 of the horn and when terminal #5 has a ground source, the horn
sounds.
HORN CIRCUIT
TROUBLESHOOTING

Horn will not work Blown #7, 15-amp fuse Replace 15-amp fuse
Faulty stalk switch Check switch, replace if neces-

sary
Faulty ground circuit Check ground circuit, repair if nec-

essary
Faulty horn Check horn , replace if necessary
55-87
66064555
18
55-88

NOTE: The cruise control circuit is shown with the cruise control switch in the “SET” position and the brakes not
applied.
NOTE: The cruise control circuit can be activated with the HST linkage either in the forward or reverse position.

travels through the #5 7.5-amp fuse and the #2, 10-amp fuse.
2. The #5 7.5-amp fuse supplies current to terminal #8-3 of the cruise control relay.
3. The #2, 10-amp fuse provides current to terminal # 5 of the cruise control switch.
Cruise Control Switch

1. When the cruise control switch is placed in the “SET” position current is transferred from the #5 terminal to
the #6 terminal.
NOTE: The cruise control switch is a momentary type switch.
2. Current travels from the #6 terminal of the cruise control switch to terminal # 8-1 of the cruise control latch
relay also terminal #6 supplies terminal #8 of the switch for the internal light bulb of the switch.
Cruise Control Latch Relay

1. The ground circuit for the coil side of the relay is provided by terminal #8-2 of the relay. The ground circuit
is completed when the cruise control switch is placed in the “SET” position, this latches terminal #2 and #3
of the cruise switch. Terminal #3 of the cruise switch is provided with a ground source when the cruise brake
switch is in the closed position (brake not applied) connecting terminals “A” and “B” of the brake switch. The
ground source is provided by the park brake interface relay and the chassis ground located on the left side
of the HPL housing.
2. When terminal #8-1 is provided with current and terminal 8-2 is has a ground source, the relay is energized,
latching terminals #8-3 and #8-5 of the relay.
3. Terminal #8-5 of the relay provides current to:
• Cruise control diode
• Cruise control magnet
4. The Cruise control diode creates a “loop” circuit for the cruise relay, current is sent through the diode to
terminal # 8-1 of the relay, allowing the relay to stay energized and latched.
55-89
Cruise Control Magnet

1. When terminal “A” of the magnet is provide with current from terminal # 8-5 of the cruise relay and terminal
“B” of the magnet is provided with a ground source from the chassis ground. The magnet energizes and locks
the HST linkage in the desired location.
2. The magnet can be deactivated by either:
• Placing the cruise control switch in the “OFF” position
• Depressing the BOTH brake pedals
Either one of these actions will interrupt the current to the magnet causing the magnet to deactivate and release
the HST linkage.
NOTE: When the brake pedals are locked together the cruise control will deactivate. Depressing only the right
or left brake pedals will not affect the cruise circuit.
55-90

TROUBLESHOOTING

Cruise will not activate Blown #5, 7.5-amp fuse Inspect and replace the 7.5-amp
fuse as necessary
Blown #2, 10-amp fuse Inspect and replace the 10-amp

fuse as necessary
Defective cruise control switch Test switch and replace as neces-

sary

Defective or stuck brake release Test brake release switch. Replace

switch as necessary.
Cruise control activates, but does Defective cruise control switch Test cruise switch and replace as
not remain in “ON” position necessary.
Defective cruise control diode Test diode and replace as neces-

sary

Cruise control magnet will not hold Cruise control magnet bracket is Adjust or tighten cruise control
hydrostatic transmission linkage in loose or improperly adjusted magnet as necessary.
position
Defective cruise control magnet Test cruise control magnet and
Excessive HST return spring pres- Reduce spring pressure

sure
55-91
66064554
19
55-92


• Terminal #3:1 of Park Brake Interface Relay
• Terminal #6-3 High Range Shift Relay
• Terminal #2 of High/Low Range Shift Switch (Standard)
High/Low Switch (s)

1. When the range shift switch is placed in the “LOW” position, current flows out of terminal #1 of the (standard)
or terminal #4 of the (optional) switch. This current from the switch flows to terminal #7-1 of the “LOW” shift
relay.
Low Shift Relay

1. When current is supplied to terminal #7-2 and a ground source to terminal #7-1 (ground source provided by
main ground, located at engine starter mounting bolt.) The relay energizes, latching terminals #7-3 and 7-5
of the relay. This cuts off the ground circuit to the High shift relay.
2. When the Low shift relay is energized, the range shift solenoid does not receive current and is not activated.
This allows the hydrostatic motor to stay in “LOW” range.
3. When the High shift relay is not energized, terminals #6-3 and #6-4 are latched. Terminal #6-4 provides
current to terminal #10 of the High/low Switch, terminal #9 of the switch is provided with a ground source and
the internal light bulb of the switch illuminates.
NOTE: “LOW” range is the default setting for the tractor hydrostatic system. When the tractor electrical system
is shutdown and reactivated the hydrostatic system will default to the “LOW” range.
55-93

TROUBLESHOOTING

Tractor will not switch into “LOW” Faulty range shift rocker switch Test and replace switch as neces-
range sary
Defective “HIGH” or “LO” shift relay Test relays and replace as neces-
sary
Defective range shift solenoid
necessary
Fault in wiring or ground terminal
as necessary.
Tractor will not switch out of “LOW” Blown #5, 7.5-amp shift control Inspect and replace the 7.5-amp
range fuse as necessary
Faulty range shift rocker switch
Test and replace switch as neces-
sary
Defective “HIGH” or “LO” shift relay
Test relays and replace as neces-
Defective range shift solenoid sary

Fault in wiring or ground terminal necessary

as necessary
“LOW” range bulb fails to illumi- Defective “LOW” range bulb Replace range shift switch
nate, but tractor shifts into “LOW”
range
55-94
PAGE LEFT BLANK
55-95
66064553
20
55-96


• Terminal #3:1 of the Park Brake Interface Relay
High/Low Switch (s)

1. When the range shift switch is placed in the “HIGH” position, current flows out of terminal #3 of the (standard)
or terminal # 5 of the (optional) switch. This current from the switch flows to terminal #101 of diode module,
through the diode module, to terminal #91 of module then to terminal #6-1 of the high shift relay.
High Range Relay

1. When current is supplied to terminal #6-1 and a ground source to terminal #6-2, the relay energizes, latching
terminals #6-3 and #6-5 of the relay. (Ground source provided through terminal #7-3 and #7-4 of the low shift
relay by main ground, located at engine starter mounting bolt.)
2. When the high shift relay is energized, terminals #6-3 and 6-5 latch.
3. Terminal #6-5 supplies current into two different paths:
• One path sends current to the range shift solenoid, the solenoid is grounded by the chassis ground, which
is located on the left side of the HPL housing. This allows the solenoid to energize and shift the hydrostatic
motor into “HIGH” range.
• The other path flows to terminal #301 of the diode module through the diode module and exists out
terminal #291. From terminal #291 current travels to terminal #91 of diode module, the diode blocks
current to terminal #101 of module. This diode forces current to travel to terminal #6-1 of high shift relay,
this current allows the relay to remain energized and keep the hydrostatic transmission in “HIGH” range.
• Terminal #301 of the diode module also supplies current to terminal #8 of the High/Low switch. Terminal
#7 of the switch is supplied with a ground source provide by the chassis ground located on the left side
of the HPL housing. This allows the internal bulb in the switch to illuminate.
55-97

TROUBLESHOOTING

Tractor will not switch into “HIGH” Blown #5, 7.5-amp shift control Inspect and replace fuse as neces-
range sary
Faulty range shift rocker switch Test and replace switch as necessary

necessary
Defective range shift diode(s) Test diode(s) and replace as

necessary

as necessary
Low charge pressure Check HST charge pressure relief

valve
Tractor will not switch out of “HIGH” Faulty range shift rocker switch Test and replace switch as necessary
range

necessary

as necessary
“HIGH” range bulb fails to illumi- Defective “HIGH” range bulb Replace range shift switch
nate, but tractor shifts into “HIGH”
range
55-98
PAGE LEFT BLANK
55-99
CHARGING CIRCUIT
66064552
21
55-100
CHARGING CIRCUIT
NOTE: The charging circuit is shown with the ignition switch in the “ACC/RUN” position and the engine running.
2. From the starter motor, current is split into two paths:
• “B” terminal of the alternator
• 50-amp main fuse
3. Current flows through the 50-amp fuse to a wire splice. The wire splice sends current:

travels through the #5 7.5-amp fuse and #1, 7.5-amp fuse.
3. The #1 7.5-amp fuse provides current to the “R” terminal of the alternator.
Alternator/Indicator Light
1. If the tractor engine is not running or the alternator is not producing a sufficient amount of charge, (with key
switch in the “ACC/RUN” position) the charge light will illuminate.
• The current for the indicator light is provided by terminal #2 of the instrument panel.
• The ground source for the indicator light is provided by terminal #6 of the instrument panel. From terminal
#6 the ground path passes through a diode which is an internal part of the instrument panel circuitry, then
to the “L” terminal of the alternator. The ground source for the “L” terminal is provided by the alternator
field coil.
• When the ground circuit is complete to terminal #6 and current is provided to terminal #2 by the #5,
7.5-amp fuse, the charge indicator light will illuminate.
2. When the tractor engine is running with the alternator rotating and the ignition switch in the “ACC/RUN”
position, the alternator produces an increased regulated voltage to the battery.
• When the alternator is producing current, the ground circuit, through the “L” terminal, for the charge
indicator light is disrupted, causing the indicator light to not illuminate.
• The “R” regulator terminal controls the voltage output from the alternator. If current is not present at the
“R” terminal the alternator will not produce current.
• The “B” terminal of the alternator is the output connection between the alternator and the battery.
55-101
CHARGING CIRCUIT
TROUBLESHOOTING

Charge light remains illuminated Faulty alternator component Test alternator and repair a neces-
sary
Short circuit to ground between Check wiring and repair as neces-

alternator and warning lamp sary
Charge light does not illuminate Blown #5, 7.5-amp instrument Inspect 7.5-amp fuse and replace
panel fuse as necessary
Faulty charge indicator bulb Inspect indicator bulb and replace

as necessary
Open charge light circuit Inspect connections, grounds, and

wiring for charge circuit and repair
as necessary
Insufficient or no battery charge, Battery charge less than 75% Test battery. Charge, add water, or
hard starting, or dim indicator light replace as necessary
Fan belt slipping Check fan belt tension, adjust as

necessary
Loose wiring connections Check wiring connections for

charge circuit, repair as necessary
Continuity fault in external wiring Check wiring harness and repair as

necessary
Blown #1, 7.5-amp alternator Inspect 7.5-amp fuse and replace

excitation fuse as necessary
Battery failure, frequent burnout of Overcharge condition Check alternator voltage output
lamps and fuses and repair as necessary
Ground circuit for alternator short- Check alternator wiring and con-
circuited nections and repair as necessary
55-102
PAGE LEFT BLANK
55-103
66064547
22
55-104

2. From the starter motor, current flows through the 50-amp fuse to the “B” terminal of the ignition switch.
travels through:
• #2, 10-amp fuse
• #5, 7.5 amp fuse
Fuse Functions
1. The #2, 10-amp fuse supplies current to:
• Main PTO Safety Start Switch

• Terminal #2 of the instrument panel
Safety Switch and Relay Functions

1. When the rear PTO is engaged the main PTO safety switch terminals #2 and #4 are open not allowing current
to be transferred to the PTO safety start relay.
2. When the PTO safety start relay does not have current supplied, the relay is not energized.
3. The non-energized relay, has terminals 1:3 and 1:4 connected.
4. Terminal 1:4 of the relay supplies the ground source to terminal #12 of the instrument panel.
PTO Indicator Light

1. When current is present at terminal #2 and a ground source supplied to terminal to terminal #12 of the
instrument panel, the PTO indicator light will illuminate.
55-105

TROUBLESHOOTING

PTO light will not illuminate Blown, #5, 7.5-amp instrument Inspect and replace fuse as
panel fuse needed
PTO indicator bulb faulty Inspect bulb and replace as

necessary

necessary.
Faulty main PTO switch Test switch and replace as

necessary
Faulty PTO safety start relay Test relay and replace as

necessary
Malfunctioning Instrument Panel Test instrument panel and replace

as necessary
PTO indicator light remains illumi- Main PTO switch improperly Check switch adjustment
nated adjusted
Defective PTO safety start relay Test relay and replace as neces-
sary

necessary.
55-106
PAGE LEFT BLANK
55-107
66064570
23
55-108

2. From the starter motor, current flows through the 50-amp fuse to the “B” terminal of the ignition switch.
travels through:
• #5, 7.5 amp fuse
Fuse Functions
1. The #5, 7.5- amp fuse supplies current to:
• Terminal #2 of the instrument panel
• Park Brake Interface Relay, terminal #3:1
Park Brake Switch and Interface Relay Functions

1. When the park brake is engaged the park brake switch terminals #2 and #4 are connected completing the
ground path to the park brake interface relay.
2. When current is supplied to terminal #3:1 and a ground source supplied to terminal #3:2 the park brake
interface relay is energized.
3. The energized relay connects terminals #3:3 and 3:5.
4. Terminal #3:5 provides a ground source for terminal # 11 of the instrument panel.
Park Brake Indicator Light

1. When current is present at terminal #2 and a ground source supplied to terminal to terminal #11 of the
instrument panel, the Park Brake indicator light will illuminate.
55-109

TROUBLESHOOTING

Park brake indicator light will not Blown #5, 7.5-amp fuse Inspect and replace fuse as
illuminate needed.
Indicator bulb faulty Inspect bulb and replace as
necessary
as necessary
Faulty Park Brake switch Test switch replace as necessary
Park brake indicator light remains Faulty Park Brake switch Test switch replace as necessary
illuminated
as necessary
55-110
PAGE LEFT BLANK
55-111
66064548
24
55-112


Temperature Gauge
1. Two ground paths allow the engine coolant temperature gauge to function.
3. The needle within the temperature gauge is controlled by the second ground path. The second ground path
exists the gauge at terminal #15 of the instrument panel to travel to the engine coolant temperature sending
unit. At the sending unit, the resistance to ground changes as the engine temperature rises or lowers. The
temperature gauge translates this resistance into movement of the gauge needle. The greater the resistance
the less needle movement and the lesser the resistance the more the needle movement.

TROUBLESHOOTING

Inoperative temperature gauge Blown #5, 7.5-amp instrument Check 7.5-amp fuse and replace as
panel fuse necessary
Defective coolant temperature Test coolant temperature sending

sending unit unit and replace as necessary
Defective temperature gauge Test temperature gauge, replace

Faulty ground for temperature Check ground terminal at starter

gauge bolt. Repair as necessary
55-113
66064549
25
55-114

NOTE: The engine low oil pressure indicator light circuit shows the ignition switch in The “ACC/RUN” position
and the tractor engine in a low oil pressure condition.


provided by terminal #1. The ground path for the indicator light travels through the engine oil pressure switch
which is grounded directly to the engine cylinder head. When the engine oil pressure drops below 6 psi the
switch closes to complete the ground path to terminal #1 of the instrument panel. This allows the low oil
pressure indicator light to illuminate, warning the operator of a potential engine problem.

TROUBLESHOOTING

Oil pressure warning light remains Low engine oil pressure Test engine lubrication system and
illuminated repair as necessary
Defective oil pressure switch Test oil pressure switch and replace
as necessary
Oil pressure circuit is short- Check oil pressure switch, ground

circuited and wires for short circuit
Defective instrument panel Test instrument panel and replace

as necessary
Oil pressure warning light will not Blown #5, 7.5-amp instrument Replace fuse as necessary
illuminate panel fuse
Inspect warning bulb and replace
Faulty oil pressure warning bulb as necessary
Check oil pressure switch connec-

Oil pressure circuit open tions and wires
55-115
FUEL LEVEL CIRCUIT
66064550
26
55-116
FUEL LEVEL CIRCUIT


Fuel Gauge
1. Two ground paths allow the fuel gauge to function.
3. The needle within the fuel gauge is controlled by the second ground path. The second ground path exists
the gauge at terminal #14 of the instrument panel to travel to the fuel level unit. At the sending unit, the
resistance to ground changes as the fuel level rises or lowers. The fuel gauge translates this resistance into
movement of the gauge needle. The greater the resistance the less needle movement and the lesser the
resistance the more the needle movement.
FUEL LEVEL CIRCUIT

TROUBLESHOOTING

Inoperative fuel level gauge Blown #5, 7.5-amp instrument Check fuse and replace as neces-
panel fuse sary
Malfunctioning fuel level sending Test fuel level sending unit and
unit replace as necessary
Improper ground circuit Check fuel level sending unit

connections and circuit grounds
and repair as necessary
Malfunctioning fuel gauge Test fuel gauge and replace

55-117
TACHOMETER CIRCUIT
66064551
27
55-118
TACHOMETER CIRCUIT

Alternator/Instrument Panel
1. Two supplied currents allow the tachometer to function.
2. First current is supplied to terminal #2 of the instrument panel by the #5 7.5-amp fuse
3. Terminal “T” of the alternator (HP12Y coded wire) provides a signal current to terminal #20 of the instrument
panel. This current controls the tachometer’s RPM reading
4. The ground source is provide by terminal #24 of the instrument panel. This is a constant ground source
TACHOMETER CIRCUIT
TROUBLESHOOTING

Tachometer does not operate when Blown #5, 7.5-amp instrument Inspect and replace fuse as neces-
tractor engine is running panel fuse sary
Defective tachometer Test tachometer and replace instru-

Tachometer pick-up wire damaged, Inspect tachometer pick-up, repair

corroded, disconnected or short- or replace as necessary
circuited
Faulty tachometer gauge ground Inspect and repair ground wire as

necessary
Defective alternator component Test alternator and components,

Inaccurate tachometer reading Malfunctioning tachometer Test tachometer and replace instru-
Loose alternator belt Adjust belt tension
55-119
BEACON CIRCUIT
66064516
28
55-120
BEACON CIRCUIT
to:
Cab Power Relay

• Fuse #25, 15-amp
4. The #25, 15-amp fuse, provides current to terminal #2 of the beacon switch..
Beacon Switch
1. When the beacon switch is place in the “ON” position current is transferred from terminal #2 to terminal #3
of the switch.
2. The #3 terminal of the switch provides current to the beacon.
Ground Sources
1. The ground source is the chassis ground located at the engine starter mounting bolt.
55-121
BEACON CIRCUIT TROUBLESHOOTING

Beacon will not work Ignition switch not in the “ON” Place ignition switch in the “ON”
position position
Faulty beacon switch Check switch, replace if neces-

sary
External power socket connection Check connector for proper con-

not making contact. tact.
Faulty Beacon Check Beacon , replace if neces-

sary
55-122
PAGE LEFT BLANK
55-123
RADIO CIRCUIT
66064518
29
55-124
RADIO CIRCUIT
to:
• #6, 15-amp fuse
6. The #6, 15-amp fuse provides current to the #22, 2-amp fuse. The 2-amp fuse provides power to the radio
for memory functions, when the key switch is in the “OFF” position.
Cab Power Relay

• Fuse #23, 10-amp
4. The #23, 10-amp fuse, provides current to terminal #3 of the radio.
Radio Functions
1. The radio terminals have the following functions:
• Terminal #3, current input (functional)
• Terminal #5, current output, left speaker
• Terminal #7, current output, right speaker
• Terminal #8, current input (memory)
• Terminal #10, ground
• Terminal #12, ground, left speaker
• Terminal #14, ground, right speaker
55-125
RADIO CIRCUIT TROUBLESHOOTING

Radio will not play Ignition switch not in the “ON” Place ignition switch in the “ON”
position position
Radio Harness connector Check connector for proper con-

not making contact tact.
Faulty radio Replace radio

Memory on radio will not function Blown #6, 15-amp fuse Replace 15-amp fuse
Faulty radio Replace radio
55-126
Chapter 7 -- Instrument Panel --

DX40--DX45 With Cab
CONTENTS

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Proof Meter (hour meter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Instrument Panel Indicator and Illumination Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bulb Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
55-1
COMPONENT OPERATION AND SERVICING
INSTRUMENT PANEL
The following components of the instrument panel
are serviced separately:
1. Lens
2. Bezel
3. Rear Cover
4. Fuel Gauge
5. Temperature Gauge
6. Indicator/Illumination Bulbs
NOTE: The proof meter and tachometer are not
serviced as a separate component. Replace the
Instrument Panel assembly if there is a performance
problem with the hour meter.
3
5
4
6
2
50054396
55-2
6 12
5 7
10
2
50035983 4 3 11 8 8 11 9
2
1. Cold Starting Indicator Light -- Illuminates 7. Temperature Gauge -- Indicates coolant tem-
when the key switch is turned to the “ACC/RUN” perature. It is activated when the key switch is
position. It remains lit for approximately four turned to the “ACC/RUN” position. The gauge will
seconds when the key is in position, during which register “cold” with the key switch in the “STOP”
time the glow plugs are heating the precombus- position. If the needle registers in the green
tion chambers of the cylinder head. range of the gauge, this indicates a normal
operating temperature. If the needle moves to
2. Engine Oil Pressure Warning Light --
the red portion of the gauge, indicating an
Illuminates with the key switch in the “ACC/RUN”
overheated condition, stop the tractor engine
position and remains lit for a short period of time
IMMEDIATELY and investigate the cause.
after the engine is started. The light indicates oil
pressure only, and goes out when sufficient oil 8. Flasher Warning Hazard Lights -- Operate
pressure is present at the oil sender. If the bulb when the flasher switch is turned on, regardless
lights during operation, stop the tractor engine of the key switch position. Use the flasher
immediately and investigate the cause. warning lights and the SMV placard when
traveling on public roads, day or night.
3. Battery Charge Warning Light -- Illuminates
when the key switch is in the “ACC/RUN” position 9. Parking Brake Light -- Illuminates if the parking
and goes out when the engine is started. If this brake is engaged when the key switch is turned
bulb lights during operation, it indicates that the from the “OFF” position.
charging system is not operating normally. As the 10. PTO “On” Indicator -- When the rear PTO
battery can become fully discharged under these position is engaged, and the key switch is in the
conditions, the problem should be investigated “ACC/RUN” or “START” position, this indicator
as soon as possible. will be illuminated amber.
4. Proof Meter -- Records the hours and portions of 11. Flasher Turn Lights -- Operate when the turn
hours that your tractor has been operated, signal switch is moved forward for right turns (the
regardless of engine RPM. Use the proof meter RH arrow will flash) or rearward for left turns (the
as a guide to determine hourly service and LH arrow will flash.) The key switch must be in the
maintenance intervals. “ACC/RUN” or “START” position for the turn
5. Fuel Gauge -- Indicates the amount of diesel fuel signals to operate.
remaining in the tank. The gauge is activated 12. PTO Speed Indicator -- Determined by the
when the key switch is in the “ACC/RUN” position of the needle on the tachometer. The
position. It will resister “empty” with the key tachometer is marked to indicate 540 PTO RPM.
switch in the “STOP” position. If the needle registers above the 540 RPM mark,
6. Tachometer -- Registers engine RPM (Revolu- this indicates a dangerous over speed condition,
tions Per Minute) The gauge is marked in and the engine RPM should be reduced
increments of 100 and will return to zero when immediately. (only on HST tractor)
the engine is not running.
55-3
Removal
Remove the two screws, 1, from each side of the 1 1
instrument panel and pull the panel assembly out of
the dash.
NOTE: Additional wire harness length is provided so

that the instrument panel can be removed from the
mounting without unplugging the harness.
50035983
COMPONENT TESTING AND REPLACEMENT

FUEL GAUGE
Testing 2
Instrument panel viewed from rear, pin #s are not
marked on panel

50043883
4
between pins: 3


Fuel Level/Gauge Reading Relationship 2 1

50043882
Gauge Reading Ohms from Sender
5
Empty 240 ohms
1/8 190 ohms
3/4 67 ohms
Full 33 ohms

open circuit is measured, the fuel gauge should be
replaced.
55-4
Replacement
1
the panel body.
50043883
6
from the panel.
2
50043881
7
circuit board and remove the fuel gauge from the 3
front on the instrument panel.
4. Insert new fuel gauge into panel, secure with face
plate retaining screw and nuts. Reassembly lens
and rear cover.
3
50043882
55-5
TEMPERATURE GAUGE
Testing 1
marked on panel
1. Remove the two retaining screws from panel, 1,

50043883
9
between pins:
3


between 223 and 301 ohms 2
1
If the resistance measure is outside the ranges or a 50043882
open circuit is measured, the temperature gauge
should be replaced. 10
Engine Temperature/Gauge Reading Relationship
Gauge Reading Temperature Ohms from Sender

Blue/Green Border Approximately 60°C (140°F) 84 ohms
Middle of Green 80°C (176°F) ± 5°C (41°F) 41 ohms
Green/Red Border 105°C (221°F) ± 3°C (37°F) 15 ohms
Replacement
2
the panel body.
50043883
11
55-6
from the panel.
3
50043881
12
circuit board and remove the temperature gauge 4
from the front on the instrument panel.
4. Insert new temperature gauge into panel, secure
with face plate retaining screw and nuts.
Reassembly lens and rear cover.
4
50043882
13
TACHOMETER
Testing
marked on panel
50043883
14
55-7
between pins: 4 1


open circuit is measured, the instrument panel
should be replaced as an assembly.
3 2
The tachometer is not serviced as a separate 50043882
component.
15
PROOF METER (hour meter)
The proof meter shares the same common current
input terminal #20 and ground terminal #2 as the
tachometer, on the instrument panel connector.
There is not a test procedure to check the proof meter

alone.
If the tachometer is working correctly and the proof

meter does not register hours, the problem exists
either in the instrument panel printed circuit board or
the proof meter itself.
The proof meter is not serviced separately and if the

proof meter does not work correctly, the instrument
panel has to be replaced.
55-8
INSTRUMENT PANEL INDICATOR AND

ILLUMINATION LIGHTS
Bulb Identification Chart
BULB # DESIGNATION CANDLE POWER

1 ILLUM - TEMP GAUGE 0.7
4 ILLUM – FUEL GAUGE 0.7
5 WARN – PTO 0.7
6 WARN – PARK BRAKE 0.7
7 HAZARD LIGHT 0.7
8 RIGHT TURN SIGNAL 0.7
9 LEFT TURN SIGNAL 0.7
10 WARN – BATT. CHARGE 0.7
11 WARN – OIL PRESSURE 0.7
12 WARN – PREHEAT 0.7
13 ILLUM – HOUR METER 0.7
3
2
1 4
9
5 7 8 10 11 12
6 13
50043882
16
55-9
Bulb Replacement
1. Remove the two retaining screws, 1,from panel 1
2. Rotate bulb assembly counterclockwise a
quarter turn and remove bulb assembly from the
instrument panel.
3. Insert bulb assembly into appropriate hole in
circuit board, turn bulb assembly a quarter turn
clockwise
4. Reassemble rear cover to instrument panel.
50043883
NOTE: All bulbs are the same candle power (0.7) and
are interchangeable in positions. Part #87300474 17
55-10
Instrument Panel Master Plug Identification -- As viewed from rear of instrument panel
50043883
18
1 5 9 13 17 21
2 6 10 14 18 22
3 7 11 15 19 23
4 8 12 16 20 24
Pin # Function Pin # Function
1. Engine Oil Pressure Indicator Light 13. Open

2. Switched Power (+) 14. Fuel Level Gauge
3. Open 15. Engine Temperature Gauge
4. Open 16. Open
5. Open 17. Trailer
6. Alternator Charging (--) 18. Open
7. Glow Plug Indicator Light 19. Right Turn Signal Indicator Light
8. Open 20. Engine RPM
9. Left Turn Signal Indicator Light 21. Open
10. Open 22. Open
11. Parking Brake Indicator Light 23. Panel Illumination
12. PTO Indicator Light 24. Constant Ground (--)
55-11
55-12

DX40--DX45 With Cab
CONTENTS

Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
55-1

Pinion Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brush Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Field Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
55-2
ALTERNATOR SPECIFICATIONS
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mitsubishi
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A007TA1777
Output Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 amp
Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Negative Ground
Rotational Direction (viewed from pulley) . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 15 mm (0.39 – 0.59 in) deflection

@ 9 – 11 kg (20 – 25 lb) of force
Adjusting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.5 – 15.0 volts
Load Characteristics
Terminal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.5 volts
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 amp minimum
Rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500
Brush Length
Wear Limit (min. length) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.20 in)
Original . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5 mm (0.728 in)
Brush Contact Rings

Wear Limit (min. diameter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1 mm (0.871 in)
Original Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7mm (0.894 in)
Bearing
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECSC8
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6303DDG
Stator Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . less than 1.0 ohm
Rotor Coil Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.0 ohms
55-3
ALTERNATOR TROUBLESHOOTING
NO CHARGING
Wiring Loose connection, short circuit Repair
Alternator Loose connection, no ground, short Repair or replace
circuit
Loose connection on RF resistor Replace
Loose connection of alternator or Repair or replace
regulator
INSUFFICIENT CHARGING
Wiring Loose connection or short circuit Repair
Insufficient brush contact Repair or replace
Loose connection of alternator and Repair
regulator
Battery Defective battery Replace
OVERCHARGE
Battery Internal short Replace
55-4
UNSTABLE CHARGING CIRCUIT

Wiring Loose connection or open wire Repair or replace
Broken brush or spring Replace
Loose connection Repair
Loose connection at alternator and Repair or replace
regulator
ABNORMAL NOISE OF ALTERNATOR

Alternator Loose mounting hardware Repair
Defective bearings Repair or replace
Rotor core and stator in contact Replace
Defective diode Replace
55-5
CHARGING SYSTEM
2 7
1
5
6
1
Op. 55 301
ALTERNATOR
Description of Operation The IC regulator, 4, is a solid state unit and can only
DX40 and DX45 cab tractors are equipped with a be serviced as an assembly.
55-amp output alternator. The alternator is equipped
with an integrated circuit (IC) regulator, meaning The internal components of the alternator are
voltage is regulated internally and electronically housed in a two-piece frame, which is divided into a
within the alternator. drive end (front) frame, 5, and a rear frame, 6. The
frame contains open slots to allow for cooling of the
The principle components of the alternator are the alternator.
stator, 1, the rotor, 2, the rectifier assembly, 3, and the
IC regulator, 4. The alternator is rotated in the frame by using a
belt-driven pulley, 7, which is powered off of the
The rectifier assembly, 3, consist of two heat sinks, engine crankshaft pulley by a belt
one positive (+) and one negative (--), and a diode
trio. The diode trio is use as a field supply diode and
is connected to terminal “L” on the alternator.
55-6
B
P
4 6
L
3
R
L R
D6
R
R6 R5 L
F R1
Dz 7
Tr2 Tr1 R2
2
E
Charging Circuit Principle of IC Regulator

The charging circuit and internal connections are The basic function of the IC voltage regulator is to
shown. The charging system consists of an IC make the terminal voltage constant by detecting the
voltage regulator, 1, (enclosed with dotted lines), a generated voltage and increasing/decreasing the
battery, 7, and connecting wires. Because of the use field current.
of IC, the voltage regulator is very compact and is
built into the alternator. As indicated, the regulator consists of two basic
sections: a voltage control device and an output
The IC voltage regulator, 1, permits the field current device to handle the field current. The voltage control
to flow directly from the diode trio, 4, to the field coil, device includes the voltage divider network, R1 and
2, without passing through the external circuit. R2, a zener diode, DZ, for voltage reference, and a
Consequently, there are no voltage drops caused by single amplifying transistor, Tr1. The output device is
the key switch or the external wiring as with a darlington-type amplifier which is called power
conventional vibrating-contact regulators mounted transistor, Tr2. The power transistor, Tr2, is placed in
separately from the alternator. To aid in initial voltage series with the alternator field coil and ground.
buildup when the engine is started, the field current
is supplied through the indicator lamp, 5, from the The signal amplifying transistor, Tr1, senses the
battery, 7. generated voltage and turns the power transistor,
Tr2, on and off many times per second most of the
Since the frequency pulse output of 1/10 the time the engine is in operation.
alternator speed develops on the “P” terminal, this
terminal is used for speed detection.
55-7
The basic operating principles are explained as 5. As the speed and voltage increase, the voltage
follows, see Figure 2: at point “A” also increases until it reaches the
limiting value set at the factory. As the zener
1. When the key switch, 6, is closed, current from diode, DZ, breaks down, current flows through
the battery, 7, flows through the indicator lamp, 5, R1, DZ, and the base-emitter circuit of Tr1 to
and resistor R6, which are in parallel to the field ground. This renders Tr1 conductive, so that
coil, 2. From here it continues to flow on through much of the current flows through the collector-
the field coil, 2, to the ground, completing the emitter circuit of Tr1. This reduces the base
circuit back to the battery, 7. current of Tr2 thereby reducing the field current.
2. When the alternator begins to rotate, AC This means that Tr1 turns on and Tr2 turns off.
voltages are generated by the stator coil, 3. The 6. When the generated voltage decreases, the
diodes in the rectifier assembly change the stator zener diode, DZ, again turns off and Tr1 also
AC voltages to DC voltage which appears turns off. This cycle repeats many times per
between ground and the “B” terminal. second, and the alternator output voltage is,
3. The stator also supplies DC field current through therefore, regulated within a narrow limit.
the diode trio, 4, the field coil, 2, the power In other words, the action is similar to the
transistor, Tr2, and then through the diodes in the conventional vibrating-contact regulator, in that
rectifier assembly back to the stator. current to the field coil, 2, is varied to limit the
4. When the generated voltage is low, no current output voltage, but in place of the voltage coil and
flows in the zener diode, DZ, since the voltage at spring system, there is a voltage divider network,
point “A” is lower than the zener voltage. R1 and R2, and a zener diode, DZ.
55-8
PRELIMINARY ALTERNATOR TESTS

Alternator Drive Belt
1. Check the alternator drive belt deflection by
applying 9--11 kg (20--25 lb) of force between the
crank pulley and the alternator pulley, 1. Belt
deflection should be 10--15 mm (0.39--0.59 in).
3
1. If the drive-belt deflection needs adjusted,
loosen the adjusting/mounting bolts, 1, and 1
adjust the alternator as needed to obtain proper
belt deflection.
4
Alternator Output
NOTE: Use the following methods if an alternator/ KEY
charging system analyzer is unavailable. SWITCH
VOLT 1 L
METER
1. Connect a 50-amp capacity test ammeter R
between the positive (+) battery cable and the ALTERNATOR AMMETER
key switch.
2. Connect a voltmeter to the battery terminal, 1, of
the alternator and to a ground source. BATTERY
3. Observe the voltmeter. The meter should
indicate battery voltage. If the voltmeter does not
read battery voltage, the wiring between the
alternator and the battery may be faulty and
5
should be repaired or replaced.
WARNING
Do not attempt to start the engine without first
shorting the wires between the ammeter leads.
Otherwise, injury or damage to the charging and
testing components may occur.
4. Use a jumper wire to short the test ammeter

leads and start the tractor engine.
55-9
5. After the tractor engine is started, remove the voltage that what is indicated when voltage is
jumper wire between the test leads of the taken at the battery. If the reading is not higher,
ammeter. the alternator is not generating enough voltage
and a component may be malfunctioning.
6. Increase the engine speed to approximately
2000 rpms and observe the ammeter reading. 8. If the ammeter indicated more than 5 amps,
continue to charge the battery until the ammeter
7. If the ammeter indicates 5 amps or less, observe
reading falls below 5 amps. If the reading does
the voltmeter reading. The voltmeter is indicating
not fall below 5 amps, test the battery or replace
adjusting voltage, which is the amount of
the battery with one that is fully charged.
increased voltage the alternator supplies to the
battery. The reading should indicate a higher
20000898
NOTE: bench testing the alternator will achieve the 11. Apply the parking brake and start the tractor
best results for the following tests. (see alternator engine. Turn on all 12-volt powered accessories
bench testing). such as headlight and indicator lights. Immedi-
ately raise engine rpms to 2000 or more to record
9. If the previous test was satisfactory, open the key the maximum value indicated on the ammeter.
switch (OFF) and connect an ammeter between 12. If the amperage value is more than 70% of the
the battery terminal “B”, of the alternator and the nominal alternator output, as described in
battery wire, as shown. alternator specifications, the alternator is consid-
10. Connect the positive (+) lead of a voltmeter to the ered to be working satisfactorily.
“B” terminal on the alternator. Connect the
negative (--) lead to a suitable ground. Confirm
that the voltmeter indicated battery voltage.
55-10
Alternator Removal
the negative battery terminal.
2. Disconnect all wiring, 1, from the rear of the 1
alternator.
3. Loosen the alternator mounting bolts, 2, and
remove the V-belt, 3, from the alternator drive
pulley. 2
4. Remove the alternator mounting bolts, 2, and
remove the alternator from the tractor engine.
3
1 8 9
5 15
4
13
3
14
7
6
12 11
2
10
20000901
8
1. Alternator Assembly Alternator Disassembly
2. Pulley Nut 1. Mark the front alternator frame, 5, the rear
3. Pulley Assembly alternator frame, 11, and the stator, 10, with
4. Bolt scribe marks to insure that the alternator is
5. Front Alternator Frame Assembly assembled as taken apart.
6. Bolt
7. Front Rotor Bearing
8. Rotor Assembly
9. Rear Rotor Bearing
10. Stator
11. Rear Alternator Frame Assembly
12. Terminal Assembly
13. IC Regulator Assembly
14. Rotor Brush and Spring
15. Rectifier
55-11
2. Remove the four (4) alternator frame retaining

bolts, 1. 3
2
3. Carefully separate the front frame, 3, and the rear 4
frame and stator, 2. The rotor assembly, 5, and
the pulley, 4, will be removed with the front frame, 1
3.
9
4. To remove the pulley nut, 1, use an impact
wrench or place the rotor, 6, into a soft jaw vice
and use a wrench. Remove the washer, 2, the
pulley, 3, spacer, 4, and the front frame, 5, from
the rotor, 6.
1
6
5
2 3 4
10
NOTE: When removing the rear rotor bearing from
the rotor, be sure to apply even pressure to the rear 1
rotor bearing. 3
5. The rear rotor bearing, 2, may be removed from

the rotor, 1, by using a bearing puller, 3.
11
55-12
6. Remove the three (3) screws, 1, which secure

the regulator/ rectifier assembly, 2, to the rear 1
alternator frame.
2
10002261
12
7. Remove the battery terminal nut, 1, from the rear
of the alternator frame. 1
8. Carefully remove the stator and the regulator/
rectifier assembly from the rear alternator frame.
20002269
13
CAUTION
2 1 3
Preheat the soldering iron before attempting to
unsolder the stator leads or the regulator/rectifi-
er assembly. To avoid any damage to the rectifier
diodes, use a pair of needle-nose pliers to
remove the excess heat from the area being
soldered. Hold the pliers just below the solder
joint on the rectifier to remove excess heat. Use
a damp cloth to cool the components once they
have been separated.
9. Unsolder the three stator leads, 1, and remove 10002262

the stator, 2, from the rectifier/regulator assem-
bly, 3. 14
55-13
10. Unsolder the IC regulator assembly, 1, from the
rectifier assembly, 2, at the solder joints, 3. 1
2
10002263
15
11. Remove the four (4) screws, 1, from the front
alternator frame, 4. Remove the retaining plate, 3
2, and the front rotor bearing, 3. 4
16
55-14
ALTERNATOR COMPONENT TESTING AND

INSPECTION
Stator
1. Using an ohmmeter, touch the ohmmeter test
probes to different leads of the stator coil.
read a resistance of less than 1 ohm, for each of
the phase wires, indicating continuity.
3. If there is no continuity, inspect the lead wire
connection for breaks. The lead wire may be
repaired with solder if damage is not excessive.
If the lead wire is good, the stator coil is faulty and
needs replaced.
17
4. Using an ohmmeter, touch one of the ohmmeter
test probes to the stator coil and the other test
probe to the stator core.
high, indicating no continuity between the coil
and the core. If there is continuity, the stator is
18
55-15
Rotor
1. Inspect the rotor brush contacts, 1, for pitting,
roughness, and dirt. If necessary, use # 600 grit
fine sandpaper to clean dirt off of the contacts. If
the contacts are pitted or damaged excessively,
replace the rotor.
SM463-173
19
2. Use a suitable measuring device to determine
the outer diameter of each brush contact. The
minimum outer diameter of the brush contacts is
22.1 mm (0.871 in).
20
probe to a brush contact. Touch the other test
probe to the remaining brush contact.
4. Observe the ohmmeter. The ohmmeter resist-
ance reading should be approximately 3 ohms.
If the reading is not as specified, the rotor is
21
55-16
NOTE: When testing the resistance between the

brush contacts and rotor poles, be sure that the 1
ohmmeter test probe touching the rotor pole is not
insulated by paint.

probe to one of the rotor brush contacts, 1, and
the other test probe to one of the rotor poles, 2.
high, indicating no continuity between the rotor
poles and brush contacts. If there is continuity, 2
the rotor is defective and needs replaced.
22
Rectifier Assembly
1. Using an ohmmeter, touch the positive (+) test
probe to the positive (+) portion of the diode
plate, 1, and the negative (−) test probe to the
other test probe to a stator coil lead connection
terminals, 2.
1 2
directions or no continuity at all, the rectifier
23
4. Using the same procedure described in the three
previous steps, test the diodes between the
negative (--) portion of the diode plate, 1, and the 1
stator lead connections, 2. Again, replace the
rectifier assembly if the diodes test defective.
24
55-17
5. Test each of the three small diodes, 1, by
touching the positive (+) ohmmeter test probe to 1
one end of a diode and the negative (−) test probe
to the opposite end of the diode.
directions, or no continuity at all, the rectifier
25
Alternator Brushes
1. Carefully clean the alternator brushes with a soft,
dry cloth and electrical component cleaner, if
available.
2. Inspect the brushes and brush springs for
corrosion, damage, stretched springs, or a 0.728″ 0.20″ (5mm)
damaged brush holder. If damaged, replace the (18.5mm)
brush assembly.
3. Use a suitable measuring device to measure WEAR LIMIT
brush wear. The minimum brush length is 5 mm NEW USED
(.020 in). If either brush is worn beyond BRUSH BRUSH
specifications, replace the brush assemblies.
26
Alternator Bearings
1. Inspect the alternator bearings for smooth
operation by spinning the bearing. Replace 2
bearings that are rough and do not rotate 3
smoothly. 1
2. Inspect the bearings for grease leakage between
the bearing seal, 3, and races, 1, and 2.
3. Inspect the inner race, 1, and the outer race, 2,
for signs of spinning in the alternator frame or on
the rotor shaft.
4. Replace bearings that are damaged in any way.
27
55-18
Drive Pulley
1. Inspect the drive pulley for a worn, bent, cracked,
1
or otherwise damaged belt groove, 1.
2. A polished surface in the bottom of the belt
groove indicates a worn pulley.
28
Alternator Frames
2
1. Inspect the bearing housing bores, 1, for scoring,
cracks or evidence that the bearing was spinning
inside the bore.
2. Inspect the frames for cracked or broken
mounting bosses, 2, or any other distortion or
damage.
1
1
2
2
29
Assembly
NOTE: When installing the rear rotor bearing, be
sure that top sleeve used to press the bearing onto
the rotor contacts the inner race of the bearing only. 2
1
1. Install the rear rotor bearing, 1, and spacer onto
the rotor by using a press, 2, and two sleeves,
such as tubing or 15-mm deep sockets, 3. The
bottom sleeve will support the rotor as the top
sleeve presses the rear bearing spacer onto the
rotor.
30
55-19
2. Install the front rotor bearing, 3, and front bearing
retaining plate, 1, into the front alternator frame, 4, 1
and secure using the four (4) retaining screws, 2.
31
3. Install the washer, 2, pulley, 3, spacer, 4, and
front frame, 5, onto the rotor, 6.
4. To install the pulley nut, 1, use an impact wrench
or place the rotor, 6, into a soft jaw vice and use
a wrench to tighten the pulley assembly to the
rotor. 1
6
5
2 3 4
32
55-20
5. Use the following guidelines when soldering

alternator components.
• Clean all terminals to be soldered and
remove excess solder.
• Preheat the soldering iron and use rosin-core
solder to solder terminals and/or wires. To
avoid damage to the rectifier diodes, use a
pair of needle nose pliers to remove excess
heat from the area being soldered. Hold the
pliers just below the solder joint on the
rectifier to remove excess heat.
• Make good, solid, solder joints for best
alternator performance.
• After soldering, quickly cool the solder joint 33
with a damp cloth.
6. Solder the IC regulator, 1, and rectifier, 2,
together. 1 2
10002263
34
7. Solder the stator leads, 1, to the terminals on the
rectifier/regulator assembly, 2. 1 3
10002262
35
55-21
NOTE: Secure the regulator/rectifier assembly to the
rear alternator frame before pressing the stator into 1
the rear frame.
2
8. Secure the regulator/rectifier assembly, 2, to the
rear alternator frame using the three (3) retaining
screws, 1. Manually press the stator assembly
into the rear alternator frame.
10002261
36
9. Install the battery terminal nut, 1, to the rear of the
alternator frame. 1
20002269
37
10. Push the brushes, 1, and springs, 3, into the
brush holder and insert a piece of wire, 2, through
the rear of the alternator frame and into the brush
3
holder to hold the brushes out of the way while
the alternator halves are being assembled.
1
38
55-22
11. Assemble the front alternator frame, 3, and rear

alternator frame, 2, together. Be sure to align the 2 3
scribe marks made when the alternator was
disassembled to insure proper reassembly. Use
the four (4) bolts, 1, to secure the front and rear 1
frames together.
39
Alternator Bench Check
1. Connect the alternator to a testing circuit, as
shown. Set the load resistance to zero (0).
AMMETER SWITCH
NOTE: Alternator rotation direction is clockwise, as A
viewed looking at the pulley.
VOLT- B
L
METER V
2. Slowly increase the alternator rotational speed R LOAD
BATTERY
and observe the voltage reading indicated on the RESISTOR
ALTERNATOR
voltmeter.
3. If the voltage is uncontrolled when increasing
alternator speed and increases above 15.5 volts,
disassemble and check the alternator for
malfunctioning components.
40
4. If the voltage reading is below 15.5 volts, set
alternator’s rotational speed to 5000 rpm and set
the load resistance to achieve maximum output
from the alternator.
5. If the amperage value is more than 70% of the
nominal alternator output as described in
alternator specifications, the alternator is consid-
ered to be working satisfactorily.
55-23
Installation
1. Align the alternator with the alternator mounting 2
holes located on the engine block and brackets.
Use the adjusting/mounting bolts, 2, to secure 1
the alternator to the mounting brackets. Be sure
to install the v-belt, 3, into the drive pulley.
2. Connect all wire terminals, 1, to rear of the
alternator.
2
41
3. Adjust the alternator drive belt deflection by
loosening the mounting bolts and moving the
alternator into or away from the engine block.
Belt deflection should be 10 – 15 mm (0.39 – 0.59
in) when applying 9 – 11 kg (20 – 25 lb) of force
between the crank pulley and the alternator
pulley, 1.
42
55-24
STARTER MOTOR SPECIFICATIONS
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Denso Corporation
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2288000-5120
Current Draw
Under Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500A @ 7.5V
No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . less than 110 amps
No Load rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000 rpm
No Load Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5 volts
Clutch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overrunning Pinion Clutch
Brush Length
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 mm
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm
Brush Spring Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7 -- 3.6 kg (5.9 -- 7.8 lb)
Commutator Diameter
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 mm
Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 mm
Commutator Insulation Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 – 0.85 mm
Armature Runout
Commutator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.02 -- 0.05 mm
Armature Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.02mm
55-25
STARTER MOTOR TROUBLESHOOTING
PINION SHAFT FAILS TO ADVANCE

Wiring Open circuit, battery, and switch Repair or replace
terminal connections
Open circuit, fuse Replace fuse
Key switch No contact Repair or replace
Starter motor Sleeve bearing burnt out Repair or replace
Lever broken Replace
Solenoid Plunger movement defective or coil Repair or replace
open or shorted
PINION MOTOR ROTATES BUT NO ROTATION TRANSMITTED TO ENGINE

Starting motor Clutch defective Replace
Orbital gear or planetary gears Replace
damaged
MOTOR ROTATES BEFORE PINION MESHES WITH RING GEAR

Starter motor Shift lever damaged Replace
Slip ring defective Replace
Pinion teeth worn Replace
Pinion push out position defective Adjust
Engine Ring gear worn Replace
55-26
PINION MESHES WITH RING GEAR BUT STARTING MOTOR FAILS TO TURN
Wiring Line connecting solenoid to battery Repair or replace
broken or defective ground
Lead wire connecting solenoid to Repair or replace
motor tightened improperly
Starting motor Ball bearing locked Replace
Brush worn Replace
Improper installation Reinstall
Brush spring defective Replace
Commutator dirty Clean
Armature of field coil defective Repair or replace
Field coil-to-brush connection Replace
defective
Solenoid Contact not touching properly Replace
Contact contacting surface Replace
roughened
Battery In discharge state Recharge or replace
MOTOR FAILS TO STOP AFTER ENGINE STARTS AND KEY SWITCH IS TURNED OFF
Key switch Switch defective Replace
55-27
Op. 55 201
STARTING SYSTEM
The starting system consists of a starter motor
equipped with an electromagnetic starter solenoid, a
key switch, a start relay, several safety switches, and
heavy-duty wiring.
STARTER COMPONENTS
4 5 6 7
2 3
1
15 8
14
10
13 11
20002284
12
43
1. Reduction Uni Cover Starter Motor Assembly
2. Armature Drive Gear The starter motor features a high-speed motor that
3. Motor/Field Coil Housing (Yoke) utilizes a gear reduction unit, an overrunning pinion
4. Permanent Magnet clutch, 12, and permanent magnets, 4, in a field coil,
5. Field Coil 5, for magnetic field induction. The reduction unit
6. Armature consists of a small drive gear, 2, on the motor
7. Brush Spring armature, 6, which drives an idler gear, 14, in the
8. Brush reduction unit. The idler gear is splined to the gear on
9. Plunger the pinion clutch housing, 12. When the starter
10. Solenoid solenoid, 10, is energized, the solenoid plunger, 9,
11. Return Spring pushes the pinion gear, 13, out, engaging with the
12. Pinion Clutch engine flywheel. The starter motor then is turning the
13. Pinion flywheel, which rotates the engine. The use of the
14. Idler Gear gear reduction unit allows use of the compact,
15. Idler Gear Roller Bearing high-speed motor and provides more torque and
power to turn the engine flywheel. The sliding pinion
mechanism is enclosed, resulting in a more durable
mechanism.
55-28
Starter Solenoid
The starter solenoid is an electromagnetic type 2 3
solenoid that is located on the bottom of the starter 1
motor assembly. The solenoid contains two coils, a
pull-in coil, 1, and a hold-in coil, 2. When the key
switch is turned to the “START” position and the
safety start relay is closed (safety switches closed),
current from the battery will energize the solenoid’s
two coils. With the coils energized, the solenoid
plunger, 4, pushes a spring, 5, which will then push
the pinion gear out to engage the flywheel. At the 4
same time, a set of contacts, 3, on the solenoid
become closed, allowing current to flow to the starter SM463-191 5
motor. Closing the contacts also supplies current to
both ends of the solenoid pull in coil, which makes the 44
coil become non-energized. The hold-in coil
continues to engage the pinion gear with the
flywheel.
Pinion Clutch
To prevent the engine from driving the starter motor 1 3
once the engine is running, the pinion gear is 6
equipped with an overrunning clutch. The clutch will 2
disengage the pinion gear from the rest of the starter
components once the engine has been started and
4
the key switch is in the “START” position. The clutch
consists of an outer gear/shell, 1, a cam with tapered
notches, 2, rollers, 3, roller springs, 6, a splined 5
pinion collar/tube that acts as a clutch hub, 4, and the
pinion shaft, 5. As the starter motor engages and
rotates, the rollers are locked against the pinion
collar with the tension provided by the roller springs.
While the rollers are locked, the clutch assembly is
locked, allowing the pinion gear to rotate the 45
flywheel. When the engine starts, the flywheel moves 1. Clutch Gear -- Outer Shell
faster than the starter motor and this causes the 2. Cam
rollers to become unlocked. With the rollers 3. Roller
unlocked, the clutch assembly is unlocked, allowing 4. Spline Tube -- Inner (Pinion Collar)
the pinion gear and shaft to turn independently of the 5. Pinion Shaft
starter motor. 6. Roller Spring
The clutch is not serviceable and is replaced as a

complete assembly. 4
2
Once the engine is started and the key switch is
released from the “START” position, the solenoid’s
pull in coil becomes energized, pulling the solenoid
plunger in, which disengages the pinion from the
flywheel.
3
1
SM463-189
46
55-29
Removal
1
the battery.
2. Disconnect the wiring harness connections, 2,
from the starter motor, 1.
3. Remove the two (2) bolts, 3, which secure the
starter assembly, 1, to the tractor engine.
2
3
10998316
47
5 6 7
4 8
3
2
1
16
15
14
10 9
11
13
12
20002285
48
55-30
Disassembly
1. Remove the field coil wire, 3, the solenoid 2
terminal, 4.
2. Remove the long through bolts, 1, securing the
motor assembly, 2 to the gear reduction unit
housing.
19985161
3 1
49
3. Slide the motor assembly, 1, from the gear
reduction unit housing, 2. 1
2
4. Remove the two (2) screws, 1, which secure the
brush cover, 2, to the motor/field coil housing, 3.
50
NOTE: Before removing the brush holder, scribe

aligning marks on the brush holder and the
motor/field coil housing. 1
2
5. Use a suitable pair of pliers to remove the
insulated armature commutator brushes, 1, from
the brush holder, 2.
6. Slide the brush holder, 2, from the armature
commutator, 3.
1
3
51
55-31
7. Remove the armature, 1, from the motor/field coil
housing, 2. The rear armature bearing, 3, is a
3
light press fit and it may be necessary to pull the
armature from the housing, gripping on the front 4
bearing, 4.
1 2
52
8. Use an impact tool, 2, to remove the two (2)
screws, 1, securing the gear reduction cover, 3,
to the starter housing.
2
1
3
20002277/20002309
53
NOTE: The pinion gear, 4, and idler gear with roller
bearings, 3, will be free to fall out when the gear 4 1
reduction unit cover, 1, is removed from the starter
assembly, 2. Use care not to lose any of these pieces.
3
9. Carefully remove the reduction unit cover, 1, from
the starter assembly, 2
SM463-199
54
55-32
10. Pull the pinion clutch assembly, 1, from the

reduction unit cover or the starter motor 1
assembly.
SM463-200
55
11. Remove the steel ball, 1, from the center of the
pinion clutch.
SM463-201
56
NOTE: When removing the idler gear and bearing,
be careful not to lose the bearing rollers contained in
the bearing.
1
12. Remove the idler gear and bearing, 1, and pinion
gear from the reduction unit cover, if they were
not removed when the reduction unit cover and
the starter motor housing was separated.
SM463-202
57
55-33
13. Remove the return spring, 1, from the
electromagnetic solenoid. 1
SM463-204
58
14. Remove the three (3) screws, 1, securing the
solenoid cover, 2, to the starter housing. Pry the
cover from the housing.
2
20002306
59
15. Remove the solenoid plunger and spring
assembly, 1, from the starter housing, 2.
2
1
20002307
60
55-34
MILLED CONDITION
EXCESSIVE WEAR
ON 2 OR 3 TEETH
MILLED TOOTH—
METAL BUILDUP
NORMAL WEAR SMALL WEAR WILL NOT PERMIT
PATTERN PATTERN MILLED GEARS
ENGAGEMENT
61
Inspection 3. Inspect the motor housing, brush cover, gear

1. Inspect the gear splines on the pinion clutch, the reduction unit, and starter housing for damage
pinion, the armature, and the intermediate gear such as cracks, fatigue, wear, etc. Replace any
for damaged or missing splines. Replace any damaged parts.
damaged parts. 4. Inspect the brush terminals, battery terminals,
2. Hold the pinion clutch housing and rotate the and motor terminals for corrosion, loose
pinion. The pinion should rotate smoothly, connections or damage. Repair or replace any
although not necessarily easily, in one direction damaged parts.
only. If the pinion can spin in both directions, the
clutch is defective and needs replaced.
55-35
5. Clean and inspect the solenoid plunger contact
ring, 1, and solenoid contacts, 2. Dirty contacts
or pitting may be cleaned with fine grit sandpaper
or a fine abrasive pad. 1
6. Inspect that all bearings rotate freely when
rotated manually by hand and are not damaged
or have excessive play. Replace any damaged
bearings.
20002308 2
62
7. Inspect the armature windings, 1, for burnt,
broken, or loose connections. 1 2
8. Inspect the commutator contacts, 2, for burnt
segments, indicating an open winding.
20002279
63
commutator diameter. The minimum commuta-
tor diameter is 34.0 mm (1.339 in). If the
commutator is worn beyond these specifications,
replace the armature.
19985170
64
55-36
10. Inspect the mica insulating valleys, 2, between

the commutator contacts, 1, for uneven wear. 2 1
Use a suitable measuring device to check the
distance, 3, between the top of the contact to the
bottom of the insulating valley. The distance
should be 0.5 – 0.8 mm (0.020 – 0.031 in). If the
distance is not within these specifications or 3
there is uneven wear, the insulating valleys may UNACCEPTABLE
be undercut with a suitable file.
20002267 CORRECT
65
NOTE: If not previously removed, the armature
bearings will need to be removed for this test. 3 1
11. Place the armature, 1, in a set of precision 5

V-blocks, 2, and use a dial indicator, 3, to
measure commutator, 4, runout and shaft, 5,
runout. Commutator runout should not be more
than 0.2 mm (0.008 in). Shaft runout should not
be more than 0.05 mm (0.002 in).
2
20002266 4 2
66
NOTE: When measuring the brush length, remove
the brush from the brush support and measure the
middle portion of the brush.

length of the four armature brushes. Compare
the measurement of each brush with brush
length specifications. If the brush is not within
specifications or is damaged in any way, replace
the brushes.
67
55-37
13. Test the brush spring tension by connecting a
spring balance to the brush spring and pulling 5.9 lbs.
until the spring moves. Observe the reading
indicated on the spring balance. If the reading is
between 2.7 – 3.6 kg (5.9 – 7.8 lb), the spring
tension is within specifications. Otherwise,
replace the brush springs. 7.8 lbs.
68
ELECTRICAL TESTING
Armature
2
1. Use a growler, 2, to inspect the armature coil, 1,
for short circuits. Replace if the armature is
shorted.
69
2. Use an ohmmeter to test for continuity in the
armature coil, 1.
3. Touch one ohmmeter test probe to a commutator
contact, 2. Touch the ohmmeter test probe to an 2
adjacent commutator contact.
4. Observe the ohmmeter. Repeat the test on each 1
adjacent commutator contact. Little or no
the armature coil is good. High resistance
indicates that the armature is defective and
needs replaced.
20002280
70
55-38
5. If the armature is tested OK, touch one ohmmeter

test probe to a commutator contact, 1. Touch the
other test probe to the armature shaft, 2.
1
2
6. Observe the ohmmeter. A high resistance
reading indicates the armature is good. Little or
no resistance indicates that the armature is
19985173
71
Brush Holder
insulated brush holder, 1, and the other test 1
probe to the brush holder plate, 2.
2. Observe the ohmmeter. Repeat the test for the
opposite insulated brush holder.
3. A reading high resistance indicates no continuity 2
and the brush holder is good. Little or no
the brush holder is defective and needs replaced.
72
Field Coil
1. Use an ohmmeter to test the field coil.
2. Touch one ohmmeter test probe to one of the field
coil brushes. Touch the other test probe to the
remaining field coil brush.
3. Observe the ohmmeter. Little or no resistance
indicates continuity and that the field coil is
functioning properly. High resistance indicates
the field coil is defective and needs replaced.
73
55-39
NOTE: Paint on the field coil/motor housing will give
a false reading when testing to see if the field coil is
grounded. Be sure to remove paint from the field
coil/motor housing.
4. If the previous test indicated the field coil was not

defective, touch one ohmmeter test probe to one
of the field coil brushes, 1. Touch the other test
probe to the field coil housing, 2.
5. Observe the ohmmeter. If the reading shows high 1
resistance, indicating no continuity, the field coil 2
is not grounded and is functioning properly. If
there is little or no resistance indicating
continuity, the field coil is defective and needs 74
replaced.
Starter Solenoid
NOTE: The following test should be performed with
the starter assembly partially assembled.
NOTE: If solenoid will not be disassembled after this

test, apply white lithium grease to the armature drive
gear, pinion clutch, idler gear and roller bearings, and
the pinion clutch steel ball and return spring.
1. Install the solenoid plunger and spring assembly,
1, into the starter housing, 2.
2
1
20002307
75
starter housing.
1
2
20002306
76
55-40
3. Install the return spring, 1, into the solenoid.

1
77
4. Install the steel ball, 1, into the center of the
pinion clutch.
78
5. Install the pinion clutch, 5, in the starter housing.
Make sure the rear clutch bearing is completely 4 1
seated in the housing.
6. Grease the idler gear bearing with petroleum jelly
3
and install the gear, 3, and bearing onto the
starter housing. Align the bearing and gear so
that it meshes with the pinion clutch and is
aligned with the hole in the housing for the pin
which the bearing rides on.
7. Install the pinion gear, 4, in the proper recess in 2
the reduction unit cover, 1, as the cover is being
79
55-41
20002277
80
CAUTION
Do not perform this test for more than 3 -- 5 3 1
seconds at a time, as damage may occur to the 2
solenoid or other components.
NOTE: Be sure to use test leads that have 14 awg

wire or thicker for this test.
9. Connect a test lead from the positive (+) terminal

of a 12-volt power source to the starter switch
terminal, 1, (spade terminal) of the starter.
SM463-216
10. Use another test lead to connect the negative (−)
terminal of the 12-volt power source to the starter 81
housing, 2.
11. Connect a second negative (--) test lead from the
12-volt power source to the field coil terminal, 3.
This completes the circuit to send current to the
hold-in and pull-in coils of the solenoid.
12. Observe the starter pinion. The solenoid should
have caused the pinion to jump forward when the
third test lead was connected to the field coil
terminal. This indicates the pull-in coil is working
properly.
13. Remove the test lead to the field coil terminal, 3,
and observe the starter pinion. The solenoid 1
3 2
should keep the pinion extended when the third
test lead is removed. This indicates the hold-in
coil is working properly.
14. If the solenoid fails to perform as described,
replace the solenoid assembly.
82
55-42
5 6 7
4 8
3
2
1
16
15
14
10 9
11
13
12
20002285
83
Assembly
NOTE: Use white lithium grease to lubricate parts
indicated. 2
1. Install the solenoid plunger, 1, into the starter

housing, 2.
1
20002307
84
55-43
starter housing.
1
2
20002306
85
3. Grease and install the return spring, 1, into the
solenoid. 1
86
4. Grease and install the steel ball, 1, into the center
of the pinion clutch.
87
55-44
5. Grease and install the pinion clutch, 5, in the

starter housing. Make sure the rear clutch 4 1
bearing is completely seated in the housing.
6. Grease the idler gear bearing and gear and
3
install the gear, 3, and bearing onto the starter
housing. Align the bearing and gear so that it
meshes with the pinion clutch and is aligned with
the hole in the housing for the pin which the
bearing rides on.
7. Install the drive gear, 4, in the proper recess in the 2
reduction unit cover, 1, as the cover is being
88
20002277
89
55-45
9
5 7
10
1
8
4
20002287 2
90
1. Front Armature Bearing 6. Brush
2. Armature 7. Brush Holder
3. Rear Armature Bearing 8. Brush Cover
4. Motor/Field Coil Housing 9. Bolt
5. Brush Spring 10. Through Bolt
9. If removed, install the front and rear bearings, 1, 11. Install the field coil brushes, 6, into the brush
3, onto the armature, 2. holder, 7, by holding the brush springs, 5, away
as the brush is being inserted into the insulated
10. Install the armature, 2, into the motor/field coil
brush holder.
housing, 4. Be sure that the rear bearing, 3, is
properly seated in the motor housing. 12. Install the brush holder, 7, onto the armature
commutator.
NOTE: When installing the field coil brushes, be sure
that the aligning marks made on the brush holder and 13. Secure the brush cover, 8, to the brush holder, 7,
motor/field coil housing will line up when the brush using the two (2) retaining bolts, 9.
holder is installed onto the armature commutator.
55-46
NOTE: Be sure the aligning marks made on the

starter housing and motor/field coil housing line up 1
when installing the motor assembly to the starter 2
assembly.
14. Install the motor assembly, 1, into the starter

assembly, 2.
91
15. Secure the motor assembly, 2, to the starter
assembly using the two (2) long through bolts, 1. 2
1
19985161
92
16. Install the field coil wire, 1, the solenoid terminal,
2.
1
2
93
55-47
No Load Test
NOTE: Before installing the starter motor to the Ammeter
tractor engine, it is recommended that a no load test
be performed on the starter motor. A
Switch
B
CAUTION S
M
Do not operate the starter for than 30 seconds at Voltmeter
Battery V
a time.
1. Connect a battery and switch to the battery

terminal of the starter and the “S” terminal of the
solenoid.
2. Connect an ammeter between the positive (+) 94
battery terminal of the battery and the battery
terminal of the starter solenoid.
3. Connect a voltmeter, after the ammeter, between
the positive (+) lead from the battery and the
negative (--) lead from the battery.
4. Close the switch and record the readings
indicated on the ammeter and voltmeter.
5. Test starter components if any abnormal
operation is noted.
6. Service limits are 11.5 volts, 110 amps maximum
at 4000 rpm.
Installation
2
1. Install the starter motor, 2, to the engine and
secure using the two (2) retaining bolts, 1. Be
sure all ground terminals are connected to the
bottom starter bolt.
2. Connect the tractor wiring harness connections,
to the starter.
battery.
3
1
10998316
95
55-48
SECTION 90 - PLATFORM - CHAPTER 1
Chapter 1 - Platform
CONTENTS

90 105 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
90 100 Rear Hood Side Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
90 110 Dash Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
90 120 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Removal -- D35, D40, D45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Removal -- DX35, DX40, DX45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
90 114 ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
90 116 D35, D40, D45 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
90 116 DX35, DX40, DX45 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
D35, D40, D45 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DX35, DX40, DX45 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
90-1

90 115 D35, D40, D45 Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
90 115 DX35, DX40, DX45 Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
90 115 D35, D40, D45 Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
90 115 DX35, DX40, DX45 Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
90-2
Op. 90 105
HOOD
Removal
1. Release the hood latch, 1, and open the hood.
1
30997551
1
2. Disconnect the headlight wire harness connec-
tor, 1, from the headlight wire, 2. 2
30997560
2
3. Loosen and remove the four hood mounting
bolts, 1. 1 1
4. Remove the hood from the tractor.
30002461
90-3
Installation
1. Position the hood so that the four mounting holes
in the hood align with the holes in the hood
mounting bracket.
2. Install and tighten the four hood mounting

bolts, 1. 1 1
30002461
4
3. Connect the headlight wire harness connector, 1,
to the headlight wire, 2. 2
4. Close and latch the hood. 1
30997560
90-4
Op. 90 100
REAR HOOD SIDE PANELS
Removal
1. Loosen and remove the two retaining bolts, 1,
that secure the left and right panels together.
2. Open the hood.
10000864
6
3. Loosen the two retaining bolts, 1, on each side of
the firewall, that secure the rear hood side
panels, 2.
4. Remove the rear hood side panels.
30002141
90-5
Installation
1. Position the rear hood side panels on the tractor,
aligning the mounting holes with the holes in the
firewall.
2. Install the two retaining bolts, 1, through the
firewall and into the rear hood side panels, 2.
Tighten the bolts.
30002141
8
3. Install and tighten the two retaining bolts, 1, that
secure the left and right panels together.
10000864
90-6
Op. 90 110
1 2
DASH CONSOLE
1
Removal
retaining screws, 1.
3
2. Remove the instrument panel, 2, from the dash
console, 3.
3. Disconnect the instrument panel wire harness
connector from the instrument panel. D35, 40, 45
DX35, 40, 45
2
1
10035024/50045711
10
4. Remove the two rear hood side panels, 1 and 2.
2
1
10000864
11
90-7
5. Disconnect the wire connector plug from the
headlight switch, 1, turn indicator switch, 2, and
the hazard flasher switch, 3.
1 3 2
50036716
12
6. Remove the cotter pin, 1, and the rivet, 2, from
the throttle lever, 3, and disconnect the throttle
cable, 4, from the throttle lever, 3.
4
2
30002405
1
13
90-8
NOTE: Step 7 applies to the D35, D40 and D45
tractors equipped with the 12 x 12 transmission only. 9
7. Remove the E-clip, 1, from the shuttle gear lever,

2. Remove the retaining ring, 3, from the knuckle, 8
4. Drive the pin, 5, from the knuckle, 4. Remove
the shuttle gear lever, 2, from the dash console,
6. Remove the E-clips, 7, from the clevis pin, 8, 6
on the main gear lever, 9. Remove the clevis pin,
2
8, and pull the main gear lever, 9, out of the dash 7
console, 6.
8. Loosen and remove the six retaining bolts 1
securing the dash console to the firewall.
9. Remove the dash console.
4 5
30002404
14
Installation
1. Position the dash console on the firewall, aligning
the mounting holes.
2. Install the six retaining bolts through the firewall
and into the dash console. Install the fuse panel
and secure with two nuts.
3. Tighten the six retaining bolts.
NOTE: Step 4 applies to the D35, D40 and D45
tractors equipped with the 12 x 12 transmission only.
4. Install the main gear lever, 9, through the dash

console, 6, and connect to the main shift shaft.
Secure the main gear lever to the main shift shaft
with the clevis pin, 8, and the E-clips, 7. Install the
shuttle gear lever, 2, through the dash console,
6, and connect to the knuckle, 4, on the shuttle
shift shaft. Drive the pin, 5, through the knuckle,
4, and the shuttle gear lever, 2.
90-9
5. Install the throttle cable, 4, on the throttle lever,
3. Secure with the rivet, 2, and the cotter pin, 1.
4
2
30002405
1
15
6. Connect the wire connector plugs to the
headlight switch, 1, the hazard flasher switch, 2,
the turn indicator switch, 3.
1 2 3
50036716
16
7. Install the rear hood side panels, 1 and 2.
8. Connect the instrument panel wire harness
connector to the instrument panel.
2
1
10000864
17
90-10
9. Install the instrument panel, 2, into the dash
console, 3, and secure with the two retaining 1 2
screws, 1. 1
D35, 40, 45
DX35, 40, 45
2
1
10035024/50045711
18
Op. 90 120
SEAT 1
2
Removal -- D35, D40, D45
1. Disconnect the seat safety start switch wire
connector, 1, from the seat start safety switch, 2.
30997564
19
90-11
2. Loosen and remove the four nuts, 1, from the
mounting bolts, 2.
3
3. Remove the seat, 3, and the safety belts, 4, from
the seat mounting plate, 5.
2
4
2
1
20002395
1
20
4. Loosen and remove the three mounting bolts, 1,
and the nut, 2, that secure the seat mounting
3
plate, 3, to the lift cover and the transmission 1
cover.
1
20002396
21
90-12
Installation
1. Install the seat mounting plate, 3, to the 3 1
transmission cover with the three mounting bolts,
1, and the nut, 2. Tighten the nut and bolts.
1
20002396
22
NOTE: Be sure to install the two spacers, 6, on the
front two mounting bolts, between the seat, 3, and
the seat mounting plate, 5. 3
2
2. Install the seat, 3, and the safety belts, 4, onto the
seat mounting plate, 5. Secure with the mounting
bolts, 2, and nuts, 1.
3. Tighten and torque the nuts, 1, to 22.6 - 28.4 N⋅m
(16.6 - 21 ft. lbs.).
4
6 2
1
1
20002395
23
90-13
4. Connect the seat safety start wire connector, 1,
to the seat safety start switch, 2.
1
2
30997564
24
SEAT
Removal -- DX35, DX40, DX45
1. Disconnect the seat safety start switch wire
connector, 1, from the seat start safety switch, 2.
1 2
30002404
25
90-14
2. Remove the two springs, 1, from the seat 4. Remove the spring brackets, 5.
base, 2.
5. Lift and remove the seat, 6, and the seat base, 2,
3. Loosen and remove the four nuts, 3, and the four from the platform, 7.
washers, 4.
6 3 4
3
3 5
4
2
1 4
30002406
26
90-15
Disassembly
NOTE: Use rebuild kit #86530936 to rebuild the seat
on the DX35, DX40 and DX45.
1. Remove the seat from the tractor.
30002436
27
2. Place the seat assembly on a bench. Fold the
seat front, and loosen the bolt, 1, in the center of
the swivel base. 1
3. Remove the seat and the swivel base from the
seat pedestal.
30002407
28
4. Lift the fore and aft slide lever, 1, and slide the
seat pedestal, 2, off of the slide base, 3.
1 2
30002408
29
90-16
5. Remove the four nuts, 1, from the carriage bolts.
1
30002409 1
30
6. Remove the slide plate, 1, from the seat
pedestal, 2. 1 2 4
7. Turn the weight adjustment knob, 3, clockwise,
until it is all the way in, to reduce the spring
tension on the extension springs, 4.
3
30002410
31
WARNING
The seat pedestal is under spring tension. The
pedestal must be compressed while removing
the nuts and carriage bolts in step 8.
8. Place the seat pedestal, 1, on the bench with the

bottom side facing up. Remove the nut, 2, from 1
the carriage bolt, on both sides of the seat base.
30002411
32
90-17
9. Remove the slider stop brackets, 1, and the
carriage bolts, 2, from the seat pedestal 2
assembly.
1
30002412
33
WARNING
Keep hands and fingers away from the scissors
linkage when removing from the slide base.
Serious personal injury could result if extremi-
ties are caught in the scissors linkage.
10. Remove the four bolts, 1, securing the top slide

base, 2. Remove the slide base, 2. 2 1
1
30002413
34
11. Remove the four bolts, 1, from the shaft blocks.
2
12. Remove the shaft blocks, 2, from the scissors
linkage, 3. 2
1
30002414
35
90-18
13. Remove the scissors linkage, 1, from the slide
base, 2. Remove the shaft blocks, 3.
3
30002415
36
14. Remove the four rollers, 1, from the scissors
linkage, 2. 1
30002416
37
15. Drive the roll pin, 1, out of the weight adjustment
knob and shaft assembly, 2. 5 3
16. Turn the adjustment knob, 3, counterclockwise to
relieve any tension on the extension springs, 4. 4
17. Disconnect the extension springs, 4, from the 2
weight adjust bar, 5.
4
1
30002417
38
90-19
18. Turn the weight adjustment knob and shaft
assembly, 1, counterclockwise and remove from 1
the weight adjust bar, 2, and the slide base, 3. 2
4
19. Remove the two thrust races, 4, and the thrust
bearing, 5, from the weight adjust shaft. 3 5
30002418
39
20. Remove the weight adjust nut, 1, and the weight
adjust spacer, 2, from the weight adjust bar, 3. 1
3
30002419
40
21. Remove the three pushnuts, 1, from the linkage
pins. 3
22. Remove the top linkage pin, 2, and roller, 3.
1
1 2
30002420
41
90-20
23. Remove the linkage pivot pin, 1, from the pivot
linkage, 2.
1 2
30002421
42
24. Remove the extension spring, 1, and the collar,
2, from the spring pin, 3. 1
30002422
3
43
25. Remove the pivot linkage, 1, from the spring
pin, 2.
1
2
30002423
44
90-21
26. Remove the remaining extension spring, 1,
collar, 2, and spring pin, 3. 1
3
2
30002424
45
Inspection
air dry.
2. Check all parts for damage or excess wear.
Assembly
1. Lightly lubricate the spring pin, 3, and the collar, 1
2, with Loctite Anti Seize 767, and install a new
extension spring, 1.
3
2
30002424
46
90-22
2. Install the pivot linkage, 1, onto the spring pin, 2,
and slide the spring pin, 2, through the holes in
the slide base, 3.
1
30002425
2
47
3. Install the remaining collar, 1, and a new
extension spring, 2, onto the spring pin, 3. Install 2
a new pushnut, 4, onto the spring pin, 3.
3
1
4
30002426
48
4. Lightly lubricate the linkage pivot pin, 1, with Anti
Seize 767, and install through the slide base, 2, 3
and the linkage pivot, 3. Secure with a new
pushnut, 4.
2 4
30002427
49
90-23
5. Lightly lubricate the top linkage pin, 1, with Anti
Seize 767, and install through the top of the pivot
linkage, 2, while installing a new roller, 3, on the
2 3
linkage pin, 1. Secure with a new pushnut, 4.
1
30002428
50
6. Lightly lubricate the new thrust bearing, 1, with
Anti Seize 767, and install along with the two new
thrust races, 2, onto the new adjustment knob 2
and shaft assembly, 3. Insert the assembly
through the hole in the slide base, 4.
1
3
30002418
51
7. Install a new weight adjust nut, 1, into the new
weight adjust bar, 2, and thread the adjustment
knob and shaft assembly, 3, into the weight
adjust nut, 1.
8. Install a new weight adjust spacer, 4,and drive a
7
3
new roll pin, 5, through the weight adjust shaft.
Connect the extension springs, 7, to the weight 4
adjust bar, 2.
1
7
5
2
30002417
52
90-24
9. Lightly lubricate the four new rollers, 1, and install
onto the scissors linkage, 2. 1
30002416
53
10. Lightly lubricate two new shaft blocks, 1,and
install on the scissors linkage, 2.
11. Install the scissors linkage, 2, onto the slide 2
base, 3.
3
12. Secure the shaft blocks to the slide base, 3, with
two screws, 4, in each side.
4
30002430 1
54
13. Lightly lubricate two new shaft blocks, 1, and
install onto the scissors linkage, 2.
1 1
30002431
55
90-25
14. Install new bumpers, 1, in the top slide base, 2.
30002433
56
15. Install the top slide base, 2, onto the scissors
linkage, and secure with two bolts, 1, on each 2 1
side. 1
30002413
57
16. Install new bumpers, 1, in the slide stop
brackets, 2. 2
1
30002412
58
90-26
17. Compress the seat pedestal assembly, 1, and
install the slide stop brackets, 2. Secure with the 1
carriage bolts, and nuts.
30002432
59
18. Position the seat pedestal assembly, 1, on the
bench with the bottom side facing up. 3
19. Install the slide plate, 2, onto the seat pedestal
assembly, 1. Secure with four carriage bolts and
nuts, 3.
2
30002434
60
20. Push down on the fore and aft slide lever, 1, and
slide the slide base, 2, onto the slide plate, 3.
2
1
30002435
61
90-27
21. Install the seat swivel base, onto the seat
pedestal assembly. Install and tighten the
retaining bolt, 1. 1
22. Install the seat assembly onto the tractor.
30002407
62
90-28
Installation 3. Install the four washers, 4, and the four nuts, 3,
1. Place the seat, 6, and the seat base, 2, on the onto the mounting bolts.
platform, 7, aligning the mounting holes in the 4. Tighten and torque the nuts, 3, to 44.1 - 55.9 N⋅m
seat base with the mounting bolts in the platform. (32.5 - 41.2 ft. lbs.).
2. Install the spring brackets, 5, onto the two rear 5. Attach the two springs, 1, to the spring brackets,
mounting bolts. 5, and the seat base, 2.
6 3 4
3
3 5
4
2
1 4
30002406
63
90-29
6. Connect the seat safety start wire connector, 1,
to the seat safety start switch, 2.
1 2
30002404
64
Op. 90 114
ROPS
NOTE: The fuel tank must be removed prior to Fixed
ROPS removal.
Removal
NOTE: Removal procedure is the same for the fixed
ROPS, and the foldable ROPS.

30997556
2. Loosen and remove the retaining bolts and nuts,
1, securing the fuel tank to the ROPS. Flip the 65
seat front, and lift the fuel tank onto the seat base,
temporarily.
3. Loosen and remove the retaining bolt, 1, from the
stabilizer bar, 2. Remove the stabilizer bar, 2,
from the stabilizer bracket. Repeat for the
opposite side.
20004155
2
66
90-30
NOTE: Illustration shows location only of attaching
hardware, 1, 2, and 3.
4. Loosen and remove the light bar retaining bolt, 1,

and the fender mounting bolts, 2 and 3. Repeat
for the opposite side. 1
6
5. Loosen and remove the stabilizer bracket
retaining bolts, 4, and the stabilizer bracket, 5.
2
Repeat for the opposite side. 3
6. Attach a suitable lifting device to a hoist, and to
the ROPS for support when removing the 1
remaining bolts.
7. Loosen and remove the retaining bolts, 6, from 2
the ROPS and the lift cover. Remove the ROPS.
3
4
20004156
5
67
Installation
NOTE: Installation procedure is the same for the
fixed ROPS, and the foldable ROPS.
1. Attach a suitable lifting device to a host, and to

the ROPS. Position the ROPS on the tractor
aligning the mounting holes, 1, with the lift cover
holes, 2. Install the mounting bolts, 3. Do not
tighten the bolts at this time.
2. Attach the stabilizer brackets, 4, to the ROPS
using the mounting bolts, 5. Repeat for the
opposite side. Do not tighten the bolts at this
time.
NOTE: Illustration shows location only of attaching
hardware, 6 and 7.
90-31
3. Install the fender mounting bolts, 6, and the light
bar retaining bolts, 7. Repeat for the opposite
side. Do not tighten the bolts at this time.
4. Tighten and torque the stabilizer bracket bolts, 5,
to 105 N⋅m (77 ft. lb.). 7
3
5. Tighten and torque the ROPS to lift cover bolts,
3, to 74 N⋅m (54 ft. lb.). 6
6. Tighten and torque the fender mounting bolts, 1
6, and the light bar retaining bolt, 7, to 25 N⋅m
(19 ft. lb.).
7
5
2
20004157
4
68
7. Install the stabilizer, 1, on the stabilizer bracket,
2, and secure with the mounting bolt, 3, and nut.
Tighten and torque the stabilizer bolts to 105 N⋅m
(77 ft. lb.).
3
20004158 1 2
69
90-32
8. Position the fuel tank, aligning the mounting
holes with the mounting holes on the ROPS.
Install the two mounting bolts, 1, and secure with
nuts. Tighten and torque the fuel tank mounting
bolts to 23 N⋅m (17 ft. lb.) maximum.
1
30997556
70
WARNING
Do not operate the tractor with the rollover
protective structure folded as a standard
operating mode. A folded ROPS does not provide
rollover protection.
WARNING
Always wear the seat belt when the tractor is
equipped with a ROPS. However, if the ROPS has
been removed from the tractor, or if the ROPS is
in the folded position, the seat belt should not be
used.
90-33
FUEL TANK 5. Loosen and remove the two mounting nuts, 6,

and bolts, 7, from the fuel tank, 8.
Removal
6. Remove the fuel tank, 8, from the tractor.
1. Drain the fuel tank, 8, into a suitable container.
7. Loosen and remove the mounting screws, 9,
2. Remove the fuel line, 1, from the fuel tank from the sending unit cover, 10. Remove the
fitting, 2. cover, 10.
3. Remove the fuel return line from the tank 8. Loosen and remove the mounting screws, 11,
fitting, 3. from the fuel sending unit, 12, and remove the
4. Disconnect the wiring plug, 4, from the fuel unit from the fuel tank, 8. Remove and discard
sending unit wire, 5. the fuel sending unit gasket, 13.
9
10
15 5
11 4
6 2
12
8 1
6 3
13
7
20002397
71
90-34
Installation
1. Install a new fuel sending unit gasket, 13, and the IMPORTANT: Do not over tighten the fuel tank
fuel sending unit, 12, to the fuel tank, 8. Secure mounting bolts.
with the mounting screws, 11.
2. Install the fuel sending unit cover, 10, and secure 6. Tighten and torque the mounting nuts, 6, to 23 N⋅m
with the mounting screws, 9. (17 ft. lbs.) MAXIMUM.
3. Position the fuel tank, 8, on the tractor, aligning 7. Connect the wiring plug, 4, to the fuel sending
the mounting holes. unit wire, 5.
4. Install the two mounting bolts, 7, through the 8. Connect the fuel return line to the tank fitting, 3.
support bar, 14, the fuel tank, 8, and the mounting 9. Connect the fuel supply line, 1, to the tank
tabs, 15 on the ROPS. fitting, 2.
5. Install the nuts, 6, onto the mounting bolts, 7.
90-35
Op. 90 116 4. If equipped, remove the loader control valve from
the right fender.
D35, D40, D45 FENDERS
5. Loosen and remove the nuts, 7, the washers, 8,
Removal the spacers, 9, and the bolts, 10, from the
1. Loosen and remove the light bar retaining bolts, fenders, 5.
1. 6. Loosen and remove the retaining bolts, 11, from
2. Loosen and remove the nuts, 2, and the bolts, 3, the fenders, 5.
that secure the light bars, 4, to the fenders, 5. 7. Remove the fenders, 5, from the tractor.
3. Disconnect the tail light wires, 6, and remove the
light bars, 4, from the tractor.
4
5
10
6
7 3
7
4
9
8
2
8
9
3
11
10
20002398 11 5
72
90-36
DX35, DX40, DX45 FENDERS 5. Disconnect the tail light wires, 9, and remove the
light bars, 7.
Removal
6. If equipped, remove the loader control valve from
1. Remove the control lever knobs from the left and the right fender, 8.
right control levers.
7. Loosen and remove the nuts, 10, the washers,
2. Loosen and remove the three bolts, 1, that 11, the spacers, 12, and the bolts, 13, from the
secure the left control pod, 2, to the left fender, 3, fenders, 3 and 8.
and the right control pod, 15, to the right
fender, 8. 8. Loosen and remove the retaining bolts, 14, from
the left and right fenders, 3 and 8.
3. Loosen and remove the light bar retaining
bolts, 4. 9. Remove the fenders, 3 and 8.
4. Loosen and remove the nuts, 5, and the bolts, 6,
that secure the light bars, 7, to the fenders, 3 and 8.
9 2
15
13
11
12
11
7 6 14
9
12
1
10
5
11
3
5
6
13
1
14 8
20002399
73
90-37
D35, D40, D45 FENDERS 4. If equipped, install the loader control valve on the
right fender.
Installation
5. Install the light bars, 4, to the fenders, 5. Secure
1. Position the fenders, 5, onto the deck and the with the bolts, 3, and the nuts, 2.
ROPS, aligning the mounting holes.
6. Install the light bars, 4, to the ROPS with the
2. Install the mounting bolts, 11. Tighten and torque bolts, 1. Tighten the attaching hardware for the
the bolts to 23 - 28 N⋅m (17 - 21 ft. lbs.). light bars.
3. Install the bolts, 10, the spacers, 9, the washers, 8, 7. Connect the wiring plug, 6, on the left and right
and secure to the ROPS with the nuts, 7. Tighten tail lights, to the tail light wiring harness.
and torque the nuts to 23 - 28 N⋅m (17 - 21 ft. lbs.).
4
5
10
6
7 3
7
4
9
8
2
8
9
3
11
10
20002398
11 5
74
90-38
DX35, DX40, DX45 FENDERS 4. If equipped, install the loader control valve on the
right fender.
Installation
5. Install the light bars, 7, to the fenders, 3 and 8.
1. Position the fenders, 3 and 8, onto the deck and Secure with the bolts, 6, and the nuts, 5.
the ROPS, aligning the mounting holes.
6. Install the light bars, 7, to the ROPS with the bolts,
2. Install the retaining bolts, 14, to the left and right 4. Tighten the attaching hardware for the light bars.
fenders, 3 and 8. Tighten and torque the bolts,
14, to 23 - 28 N⋅m (17-21 ft. lbs.). 7. Install the left control pod, 2, onto the left fender,
3. Secure with the bolts, 1.
3. Install the bolts, 13, the spacers, 12, the washers,
11, and secure to the ROPS with the nuts, 10. 8. Install the right control pod, 15, onto the right
Tighten and torque the bolts, 14, to 23 - 28 N⋅m fender, 8. Secure with the bolts, 1.
(17 - 21 ft. lbs.). 9. Connect the wiring plugs, 9, on the left and right
tail lights to the tail light wiring harness.
9 2
15
13
11
12
11
7 6 14
12
1
10
5
11
3
5
6
13
1
14 8
20002399
75
90-39
Op. 90 115 RIGHT SIDE
D35, D40, D45 DECK 1. Disconnect the brake return spring from the
deck, 8.
Removal
2. Disconnect the foot throttle return spring, 9, from
LEFT SIDE the linkage, 11.
1. Disconnect the clutch return spring from the 3. Remove the throttle cable, 10, from the
deck, 7. linkage, 11.
2. Loosen and remove the bolts, 1, and the 4. Disconnect the wire harness plug from the
washers, 2. parking brake safety switch, 12.
3. Loosen and remove the bolts, 3, and the 5. Loosen and remove the bolts, 13, and the
washers, 4. washers, 14.
4. Loosen and remove the bolts, 5, and the 6. Loosen and remove the bolts, 15, and the
washers, 6. washers, 16.
5. Loosen and remove the bolts, and the washers, 7. Loosen and remove the bolts, and the washers,
securing the fender to the deck, 7. securing the fender to the deck, 8.
6. Remove the wire harness from the underside of 8. Remove the wire harness from the underside of
the deck, 7. the deck, 8.
7. Remove the deck, 7. 9. Remove the deck, 8.
90-40
1
8
7
15
13
10 2
9
2
14 15
16
4
1
11
3
6
5
12
30002400
76
90-41
DX35, DX40, DX45 DECK 3. Loosen and remove the retaining bolts, 1, and
remove the floor mat, 2, from the deck, 3.
Removal
4. Remove the control pods, 4 and 5, from the
1. Remove the seat from the tractor. fenders.
2. Remove the tool box from the left fender.
1
3
1
20002399
77
90-42
5. Remove the cotter pins, 1, and the retaining pins, 7. Disconnect the wiring harness plug from the
2, from the left side control lever linkage, 3. Cruise Control switch.
6. Remove the control lever shaft bolts, 4, and
remove the levers, 5. Repeat for the right side
control levers.
5
4
30002401
78
90-43
8. Remove the cotter pin, 1, and the washer, 2, from 10. Disconnect the wiring plug from the park brake
the parking brake lever, 3. Remove the parking switch, 8.
brake lever, 3, up through the deck.
11. Disconnect the two brake pedal return springs, 9,
9. Remove the cotter pin, 5, and the washer, 6, from from the deck.
the park brake rod, 7. Remove the return spring,
4, and the park brake rod, 7, from the park brake
linkage.
3
2
4
1
7
6 5
8
30002402
79
90-44
12. Remove the bolts, 1, from the access cover, 2, 15. Remove the four mounting bolts, 11, and the four
and remove the cover, 2, from the deck, 3. washers, 12, from the deck, 3.
13. Remove the hitch pin, 4, from the HPL control 16. Disconnect the wiring harness at any attachment
rod, 5. Remove the HPL control rod, 5, from the points on the underside of the deck, 3.
deck, 3.
17. Loosen and remove the bolts that secure the
14. Loosen and remove the four nuts, 6, washers, 7, fenders to the deck, on both sides if the tractor.
dampers, 8, bushings, 9, and washers, 10.
18. Remove the deck, 3, from the tractor.
2 1
11 12
11
3
11
10
10
9
9
8
10
7
5 9
8 6
7
8
8
7
4 7
6
6
6
30002403
80
90-45
D35, D40, D45 DECK RIGHT SIDE

Installation 1. Position the deck, 8, on the tractor.
2. Attach the wire harness holders to the underside
LEFT SIDE of the deck.
1. Position the deck, 7, on the tractor. 3. Install the bolts and washers, through the fenders
2. Attach the wire harness holders to the underside and into the deck, 8.
of the deck. 4. Install the bolts, 13, and the washers, 14.
3. Install the bolts and washers, through the fenders 5. Install the bolts, 15, and the washers, 16.
and into the deck, 7.
6. Connect the wire harness plug to the parking
4. Install the bolts, 1, and the washers, 2. brake safety switch, 12.
5. Install the bolts, 3, and the washers, 4. 7. Connect the throttle cable, 10, to the foot throttle
6. Install the bolts, 5, and the washers, 6. linkage, 11.
7. Tighten all of the mounting bolts. 8. Connect the foot throttle return spring, 9, to the
linkage, 11.
8. Connect the clutch return spring to the deck, 7.
9. Connect the brake return spring to the deck, 8.
90-46
1
8
7
15
13
10 2
9
2
14 15
16
4
1
11
3
6
5
12
30002400
81
90-47
DX35, DX40, DX45 DECK 5. Install the washers, 10, the bushings, 9, the
dampers, 8, the washers, 7, and the nuts,
Installation 6.Tighten the mounting bolts and nuts.
1. Position the deck, 3, on the tractor. 6. Install the HPL control rod, 5, through the deck,
2. Install the bolts and washers, through the fenders 3, and connect to the HPL shaft. Secure the
and into the deck, 3. HPL control rod, 5, to the HPL shaft with the
hitch pin, 4.
3. Attach the wire harness holders to the underside
of the deck. 7. Install the access cover, 2, onto the deck, 3, and
secure with the bolts, 1.
4. Install the four bolts, 11, and the four washers,
12, into the deck, 3.
2 1
11
12
11
3
11
10
10
9
9
8
10
7
5 9
8 6
7
8
8
7
4 7
6
6
6
30002403
82
90-48
8. Connect the two brake pedal return springs, 9, to 5. Attach the return spring, 4, to the park brake
the deck. rod, 7.
9. Connect the wiring plug to the park brake safety 11. Install the parking brake lever, 3, down through
switch. the deck, and attach to the park brake linkage.
Secure with a washer, 2, and a cotter pin, 1.
10. Connect the park brake rod, 7, to the park brake
linkage. Secure with a washer, 6, and a cotter pin,
3
2
4 1
7
6 5
8
30002402
83
90-49
12. Connect the wiring harness plug to the cruise 14. Attach the linkage to the levers, 5, and secure
control switch. with the retaining pins, 2, and the cotter pins, 1.
Repeat for the opposite side.
13. Install the control levers, 5, on the deck, and
secure with the control lever shaft retaining bolts,
4. Repeat for the opposite side.
5
4
30002401
84
90-50
15. Install the control pods, 4 and 5, onto the fenders. 17. Install the tool box onto the left fender.
16. Install the floor mat, 2, onto the deck, 3, and 18. Install the seat onto the tractor.
1
3
1
20002399
85
90-51
90-52
DX40--DX45 With Cab
CONTENTS

Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear Hood Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Dash Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Washer Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Door Handle and Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Door Striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
90-1

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Cab Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cab Lifting Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
90-2
HOOD
Removal
1. Release the hood latch, 1, and open the hood.
1
30997551
1
2. Disconnect the headlight wire harness connec-
tor, 1.
3. Remove the hood struts, 2.
4. Loosen and remove the four hood mounting 3
nuts, 3. 3
1
5. Remove the hood from the tractor.
2
86064824
2
Installation
1. Position the hood so that the four mounting holes
in the hood align with the holes in the hood
mounting bracket.
1
2. Install and tighten the four hood mounting 1
nuts, 1. 3
2
3. Reattach the hood struts, 2.
4. Connect the headlight wire harness connector, 3.
5. Close and latch the hood.
86064824
3
90-3
REAR HOOD PANELS

Removal
1. Open the hood.
2. Remove the two bolts, 1, that secure the left and
right side covers, 2.
3. Remove the rear hood side panels. 1
86064081
4
4. Remove the wiper arm cover, 1.
5. Remove the wiper arm retaining nut, 2. Remove
the wiper arm assembly.
1
86064041
5
6. Remove the washer hose, 1, going to the washer
nozzle.
7. Remove the upper bolt, 2, securing the cover.
2
86064042
6
90-4
8. Remove the cover bolts, 1.
9. Carefully remove the rear upper cover and seal
(not shown). 1
1
NOTE: It may be easier to lower the hood to remove
the cover.
86064824
7
Installation
1. Carefully install the rear upper cover and seal 1
(not shown). 1
2. Install the cover bolts, 1.
86064824
8
3. Install the washer hose, 1, going to the washer
nozzle.
4. Install the upper bolt, 2, to secure the cover.
2
86064042
9
90-5
5. Install the rear hood side panels, 1, into the
rubber seal, 2.
6. Install the two bolts, 3, that secure the left and
right side covers.
2
86064081
10
7. Install the wiper arm assembly. Secure the wiper
arm with retaining nut, 1.
8. Install the wiper arm cover, 2.
1
9. Close the hood.
86064041
11
DASH CONSOLE
3 2
Removal
retaining screws, 1.
2. Remove the instrument panel, 2, from the dash
console, 3. 1 1
3. Disconnect the instrument panel wire harness
connector from the instrument panel.
86064793
12
90-6
4. Remove the two side panels, 1 and 2.
5. Disconnect the harness to the keyswitch, 3. 3
1
86064803
13
6. Disconnect the wire connector plug from the
headlight/turn signal switch, 1, the worklights
switch, 2, and the hazard flasher switch, 3.
7. Remove throttle handle by removing screw, 4.
1
3
2
4
86064793
14
8. Loosen and remove the retaining bolts, 1,
securing the dash console to the firewall.
9. Remove the dash console.
86064799
15
Installation
1. Position the dash console on the firewall, aligning
the mounting holes.
2. Install the retaining bolts through the dash
console and into the firewall.
3. Tighten the retaining bolts.
90-7
4. Install the throttle handle, 1, on the throttle lever.
Secure with screw, 2.
5. Connect the wire connector plugs to the
headlight/turn signal switch, 3, the hazard flasher
switch, 4, and worklights switch, 5.
3 5
4
1
2
86064793
16
6. Connect the instrument panel wire harness
connector to the key switch, 1. 1
7. Install the side panels, 2 and 3.
2 3
86064803
17
8. Install the instrument panel, 1, into the dash
console, 2, and secure with the two retaining 2 1
screws, 3.
3
3
86064793
18
90-8
OPERATOR’S SEAT
Removal 1
1. Pull lever, 1, and push seat rearward. Remove
both M8 x 30 mm internal hex head screws and
washers, 2.
2 2
86064039
19
2. Pull lever again and move the seat forward.
Remove both M8 x 30 mm internal hex head
screws and washers, 1.
3. Disconnect the seat switch, 2. 2
4. Remove the seat assembly from the cab.
IMPORTANT: Seat is very heavy. Use caution when 1

removing from the cab. Serious injury can occur to
self and/or seat assembly if dropped.
86064040
20
Disassembly
NOTE: Use rebuild kit #86530936 to rebuild the seat
on the DX40 and DX45.
1. Remove the seat from the tractor.
30002436
21
90-9
2. Place the seat assembly on a bench. Fold the
seat front, and loosen the bolt, 1, in the center. 1
3. Remove the seat from the seat pedestal.
66064043
22
4. Remove the fore and aft slide lever, 1, and slide,
2, by removing the two nuts and washers, 3, on
each slide.
3 3
1 2
66064043
23
5. Turn the weight adjustment knob, 1, clockwise,
until it is all the way in, to reduce the spring
tension on the extension springs.
1
66064043
24
90-10
WARNING
1
The seat pedestal is under spring tension. The
pedestal must be compressed while removing
the nuts and carriage bolts in step 6.
6. Place the seat pedestal, 1, on the bench with the

bottom side facing up. Remove the nut, 2, from
the carriage bolt, on both sides of the seat base.
30002411
25
7. Remove the slider stop brackets, 1, and the
carriage bolts, 2, from the seat pedestal
assembly. 2
30002412
26
WARNING 1
2
Keep hands and fingers away from the scissors 1
linkage when removing from the slide base.
Serious personal injury could result if extremi-
ties are caught in the scissors linkage.
8. Remove the four bolts, 1, securing the top slide

base, 2. Remove the slide base, 2.
30002413
27
90-11
9. Remove the four bolts, 1, from the shaft blocks.
2
10. Remove the shaft blocks, 2, from the scissors
linkage, 3. 2
1
30002414
28
11. Remove the scissors linkage, 1, from the slide
base, 2. Remove the shaft blocks, 3.
3
30002415
29
12. Remove the four rollers, 1, from the scissors
linkage, 2. 1
30002416
30
90-12
13. Drive the roll pin, 1, out of the weight adjustment
knob and shaft assembly, 2. 5 3
14. Turn the adjustment knob, 3, counter clockwise
to relieve any tension on the extension 4
springs, 4.
2
15. Disconnect the extension springs, 4, from the
weight adjust bar, 5.
4
1
30002417
31
16. Turn the weight adjustment knob and shaft
assembly, 1, counter clockwise and remove from 1
the weight adjust bar, 2, and the slide base, 3. 2
4
17. Remove the two thrust races, 4, and the thrust
bearing, 5, from the weight adjust shaft. 3 5
30002418
32
18. Remove the weight adjust nut, 1, and the weight
adjust spacer, 2, from the weight adjust bar, 3. 1
3
30002419
33
90-13
19. Remove the three pushnuts, 1, from the linkage
pins. 3
20. Remove the top linkage pin, 2, and roller, 3.
1
1 2
30002420
34
21. Remove the linkage pivot pin, 1, from the pivot
linkage, 2.
1 2
30002421
35
22. Remove the extension spring, 1, and the collar,
2, from the spring pin, 3. 1
30002422
3
36
90-14
23. Remove the pivot linkage, 1, from the spring
pin, 2.
1
2
30002423
37
24. Remove the remaining extension spring, 1,
collar, 2, and spring pin, 3. 1
3
2
30002424
38
Inspection
air dry.
2. Check all parts for damage or excess wear.
Assembly
1. Lightly lubricate the spring pin, 3, and the collar, 1
2, with Loctite Anti Seize 767, and install a new
extension spring, 1.
3
2
30002424
39
90-15
2. Install the pivot linkage, 1, onto the spring pin, 2,
and slide the spring pin, 2, through the holes in
the slide base, 3.
1
30002425
2
40
3. Install the remaining collar, 1, and a new
extension spring, 2, onto the spring pin, 3. Install 2
a new pushnut, 4, onto the spring pin, 3.
3
1
4
30002426
41
4. Lightly lubricate the linkage pivot pin, 1, with Anti
Seize 767, and install through the slide base, 2, 3
and the linkage pivot, 3. Secure with a new
pushnut, 4.
2 4
30002427
42
90-16
5. Lightly lubricate the top linkage pin, 1, with Anti
Seize 767, and install through the top of the pivot
linkage, 2, while installing a new roller, 3, on the
2 3
linkage pin, 1. Secure with a new pushnut, 4.
1
30002428
43
6. Lightly lubricate the new thrust bearing, 1, with
Anti Seize 767, and install along with the two new
thrust races, 2, onto the new adjustment knob 2
and shaft assembly, 3. Insert the assembly
through the hole in the slide base, 4.
1
3
30002418
44
7. Install a new weight adjust nut, 1, into the new
weight adjust bar, 2, and thread the adjustment
knob and shaft assembly, 3, into the weight
adjust nut, 1.
8. Install a new weight adjust spacer, 4,and drive a
7
3
new roll pin, 5, through the weight adjust shaft.
Connect the extension springs, 7, to the weight 4
adjust bar, 2.
1
7
5
2
30002417
45
90-17
9. Lightly lubricate the four new rollers, 1, and install
onto the scissors linkage, 2. 1
30002416
46
10. Lightly lubricate two new shaft blocks, 1,and
install on the scissors linkage, 2.
11. Install the scissors linkage, 2, onto the slide 2
base, 3.
3
12. Secure the shaft blocks to the slide base, 3, with
two screws, 4, in each side.
4
30002430 1
47
13. Lightly lubricate two new shaft blocks, 1, and
install onto the scissors linkage, 2.
1 1
30002431
48
90-18
14. Install new bumpers, 1, in the top slide base, 2.
30002433
49
15. Install the top slide base, 2, onto the scissors
linkage, and secure with two bolts, 1, on each 2 1
side. 1
30002413
50
16. Install new bumpers, 1, in the slide stop
brackets, 2. 2
1
30002412
51
90-19
17. Compress the seat pedestal assembly, 1, and
install the slide stop brackets, 2. Secure with the 1
carriage bolts, and nuts.
30002432
52
18. Position the seat pedestal assembly, 1, on the
bench with the bottom side facing up.
1
19. Install the slide plate, 2, onto the seat pedestal
assembly, 1. Secure with four nuts and washers,
3.
3 3
2 2
66064043
53
20. Install the seat base, onto the seat pedestal
assembly. Install and tighten the retaining bolt, 1.
1
21. Install the seat assembly onto the tractor.
66064043
54
90-20
Installation
1. Install the seat assembly in the cab.
2. Install both M8 x 30 internal hex head screws and
washers, 1. 2
3. Connect the seat switch, 2.
IMPORTANT: Seat is very heavy. Use caution when 1
installing into the cab. Serious injury can occur to self
and/or seat assembly if dropped.
86064040
55
4. Pull lever, 1, and push seat rearward. Install both
M8 x 30 mm internal hex head screws and
washers, 2. 1
2
2
86064039
56
FRONT WIPER MOTOR
1
Removal
1. Remove the instrument cluster, 1, by removing
the two retaining screws, 2.
2
2
86064793
57
90-21
2. Remove the wiper arm cover, 1.
3. Remove the wiper arm retaining nut, 2. Remove
the wiper arm assembly.
1
86064041
58
4. Open the hood.
5. Remove the two bolts, 1, that secure the left and
right side covers, 2.
6. Remove the rear hood side panels.
1
2
86064081
59
7. Remove the washer hose, 1, going to the washer
nozzle.
8. Remove the upper bolt, 2, securing the cover.
2
86064042
60
90-22
9. Remove the cover bolts, 1.
10. Carefully remove the rear upper cover and seal 1
(not shown). 1
NOTE: It may be easier to lower the hood to remove
the cover.
86064824
61
11. Remove the black plastic dust cap, 1.
1
12. Remove the nut, 2, retaining the motor to the 2
firewall.
13. Remove the nut, 3, washer, 4 and rubber washer,
5.
3
4 5
66064044
62
14. Remove the wiper motor, 1 and washer, 2, from
inside the cab.
2
1
66064044
63
90-23
Installation
1. Install the wiper motor, 1 and washer, 2, from
inside the cab.
2
1
66064044
64
2. Install the rubber washer, 1, washer, 2 and
secure with nut, 3. 5
4
3. Install the nut, 4, to secure the motor to the
firewall.
4. Install the black plastic dust cap, 5.
3
2 1
66064044
65
5. Carefully install the rear upper cover and seal
(not shown).
1
6. Install the cover bolts, 1. 1
86064824
66
90-24
7. Install the washer hose, 1, going to the washer
nozzle.
8. Install the upper bolt, 2, to secure the cover.
2
86064042
67
9. Install the rear hood side panels, 1, into the
rubber seal, 2.
10. Install the two bolts, 3, that secure the left and
right side covers. 2
3
1
86064081
68
11. Install the wiper arm assembly. Secure the wiper
arm with retaining nut, 1.
12. Install the wiper arm cover, 2.
2
13. Close the hood.
86064041
69
90-25
WASHER TANK
Removal
1. Disconnect the electrical connectors, 1, at each
washer motor.
NOTE: The left tire is removed for clarity.
1
86064045
70
2. Disconnect each washer hose, 1, from each
motor.
86064046
71
3. Remove the washer bottle, 1, from the left pillar
bracket, 2, by pushing upward.
86064047
72
90-26
Installation
1. Install the washer bottle, 1, in the left pillar
bracket, 2, by pushing downward.
86064047
73
2. Attach each washer hose, 1, to each motor.
86064046
74
3. Connect the electrical connectors, 1, at each
washer motor.
NOTE: The left tire is removed for clarity.
1
86064045
75
90-27
REAR WIPER MOTOR

Removal
1. Remove the cover, 1, on wiper arm, 2 and 1
remove the retaining nut, 3. Remove the wiper
arm.
2 3
86064048
76
2. Remove the plastic cover, 1, protecting the
components.
86064049
77
3. Remove the nut, 1, securing the wiper motor.
4. Remove the metal washer, 2.
86064050
78
90-28
5. On the inside of the glass, remove the cover, 1,
to the wiper motor assembly.
86064815
79
6. Disconnect the harness, 1, (connector not
shown) at the wiper motor harness, 2, (connector
not shown).
7. Remove switch, 3, from cover.
1
3
2
86064051
80
8. Remove the washer hose, 1.
9. Remove the two nuts and serrated lock washers, 2
2, that secure the wiper motor assembly, 3, to the 1
glass.
86064052
2
81
90-29
Installation
1. Install the wiper motor assembly, 1 on studs 2
coming through the glass. Secure with two nuts 3
and serrated lock washers, 2.
2. Install the washer hose, 3.
1
86064052
2
82
3. Connect the harness, 1, (connector not shown)
to the wiper motor harness, 2, (connector not
shown).
4. Install switch, 3, in cover.
1
3
2
86064051
83
5. Insert the wire harness in cover and install the
cover, 1, to the wiper motor assembly.
86064815
84
90-30
6. Install the metal washer, 1, against the rubber, 2,
in the glass. Install the washer with the lip facing
the rear of the tractor.
7. Install the nut, 3, securing the wiper motor.
2
86064050
85
8. Install the plastic cover, 1, protecting the
components.
86064049
86
9. Install the wiper arm, 1.
10. Install and secure the retaining nut, 2.
11. Install the cover, 3, on wiper arm. 3
1
2
86064048
87
90-31
DOOR HANDLE AND LATCH

Removal
1. Remove the cover, 1, by removing screw, 2.
2. Remove the two screws, 3, that secure the latch 5
4
assembly, 4, to the mounting bracket, 5.
1
2
3
66064053
88
3. Remove the jam nut, 1 and washer, 2.
4. Remove the lower bolt and washer, 3. Remove
2
the door handle.
1
86064054
89
Installation
1. Install the door handle and secure with the lower
2
bolt and washer, 1.
3
2. Install the washer, 2 and jam nut, 3.
86064054
90
90-32
3. Install the latch assembly, 1, to the mounting
bracket, 2 and secure with two screws, 3.
4. Install the cover, 4 and secure with screw, 5.
2 5
3 4
66064053
91
DOOR STRIKER
Replacement
1. Remove the nut, 1 and washer, 2, which secures
the striker protector, 3, washer, 4 and striker, 5.
2. Install the striker assembly as shown and secure
with the washer, 2 and nut, 1.
1
5 3 2
4
66064055
92
Adjustment
1. Loosen nut, 1 and move the striker assembly to
the desired position in order to make the door
shut and seal properly.
66064055
93
90-33
CAB DOOR
1
CAUTION
When replacing a door, have an assistant help in
removing the door from the cab. Serious injury
and/or damage to the door can occur.
Remove 2 2
1. Remove the door shock, 1, by removing the
spring clip, 2, on each end of the shock.
2. Pry the shock away from each mounting flange.
86064056
94
3. Remove the bolts, 1, washer, 2 and nut, 3, which
secures each door hinge. 1
4. Remove the door from the cab.
3
2
2
1
3
86064057
95
Installation
1 2
1. Install the door on the cab hinge brackets, 1.
2. Install the bolts, 2, washer, 3 and secure with nut, 4
4. 3
IMPORTANT: The door must be installed with the
hinges sitting on top of the cab hinge supports.
1
2
3
86064057
4
96
90-34
3. Push the shock onto each mounting flange.
4. Secure the door shock, 1, with the spring clip, 2. 1
5. Adjust the door as necessary.
2 2
86064056
97
CAB REAR WINDOW
CAUTION
When replacing the rear window, have an
assistant help in removing the window assembly
from the cab. Serious injury and/or damage to the 1
window can occur.
Removal
1. On the inside of the glass, remove the cover, 1,
to the wiper motor assembly and disconnect the
electrical connector and washer hose, (not 86064815
shown).
98
2. Unlock the window by turning the handle, 1,
clockwise. 1
NOTE: The handle is shown in the locked position.
86064814
99
90-35
3. Remove the window shock, 1, by removing the
spring clip, 2, on each end of the shock.
4. Carefully pry the shock away from each 2
mounting flange.
2
20064058
100
5. Remove the hinge pins, 1, by removing the
retaining ring, 2.
6. Remove the window assembly.
1
1 2
66064816
101
Installation
1. Install the window assembly so that the window
hinges are inside the mounting flanges on the
cab.
2. Insert a pin, 1, through each hinge and flange and
secure with a retaining clip, 2.
1
1 2
66064816
102
90-36
3. Push the shock onto each mounting flange.
4. Secure the window shock, 1, with the spring clip,
2. 2
2
20064058
103
5. Lock the window by turning the handle, 1,
counterclockwise, as shown. 1
86064814
104
6. Attach the washer hose, reconnect the harness
connectors and insert the wire harness in cover.
7. Install the cover, 1, to the wiper motor assembly.
86064815
105
90-37
FUEL TANK
Removal 1
1. Drain the fuel into a clean suitable container.
2. Pinch off the feed tube, 1, on the bottom side of
the fuel tank and remove the hose from the tank.
86064061
106
3. Remove the SMV mounting bracket side braces,
1, by removing the bolt and washer, 2. 1
4 3
4. Insert a 17 mm wrench into cavity between the 2
fuel tank and cab frame in order to hold the nut
and washer.
5. Remove bolt, 3, which secures the SMV
mounting bracket assembly.
6. Repeat steps 3, 4 and 5 for the other side of the
SMV bracket assembly.
7. Remove the SMV bracket, 4, from the tractor.
86064062
107
8. While removing the tank, remove the cover, 1, by
removing the screws, 2.
1
86064063
108
90-38
9. Disconnect the electrical connections, 1 and the
fuel return line, 2. 3
10. Remove the retaining bracket by removing the
bolt and washer, 3.
11. Remove the tank from the tractor. 2
86064064
109
Installation
3
1. Install the tank into the tractor.
2. Connect the electrical connections, 1 and the fuel
return line, 2.
3. Install the retaining bracket by securing the bolt 2
and washer, 3.
86064064
110
4. Install the cover, 1 and secure with screws, 2.
1
86064063
111
90-39
5. Install the SMV mounting bracket, 1. Install side
brace, 2 and secure with bolt and washer, 3. 2
1 4
6. Install bolt, 4, through the SMV mounting bracket
3
assembly and secure with washer and nut, not
shown.
7. Insert a 17 mm wrench into cavity between the
fuel tank and cab frame in order to hold the nut
and washer.
8. Repeat steps 5, 6 and 7 for the other side of the
SMV bracket assembly.
86064062
112
9. Connect the feed line, 1, to the port on the
underside of the tank.
1
10. Refill the fuel tank and check for leaks.
86064061
113
FENDERS
Removal
1. Place jack stands under the rear axle, not shown.
2. Remove the wheel, 1, from the tractor.
86064060
114
90-40
3. Remove the fifteen bolts and washers, 1, which
secures the fender to the cab.
1
86064059
115
Installation
1. Install the fender to the cab and secure the fender
with fifteen bolts and washers, 1. 1
86064059
116
2. Install the wheel, 1, onto the tractor. Torque the
lug bolts to 129 N⋅m (95 ft-lb).
3. Remove the jack stands from under the rear axle,
not shown.
86064060
117
90-41
CAB
Removal
1. Place jack stands under the rear axle, not shown.
2. Remove the rear wheels, 1, from the tractor.
86064060
118
3. Remove the fifteen bolts and washers, 1, which
secures the fender to the cab.
4. Disconnect the linkages, 2, going to the PTO, 1
FWD, Height and Range levers in the cab.
5. Repeat procedure for other fender and linkages.
86064059
119
6. Remove the hair pin, 1 and disconnect the rod,
2, which connects to the HPL Drop Rate Control
Valve, 3. 1
86064529
120
90-42
7. Remove the fuel tank, 1, as described in this
section.
86064812
121
hoses, 1, from the engine.
86064535
122
9. Evacuate the A/C system as described in Section
50 of the repair manual. 1
10. Disconnect the High pressure line going to the
receiver/drier, 1.
11. Remove the low pressure hose going into the a/c 2
compressor, 2.
12. Cap off all connections to keep moisture and
86063996
123
90-43
13. Disconnect the electrical harness connectors, 1,
at the cab.
10054350
124
14. Remove the ground cable, 1, located on the left
side of the firewall, just above the starter.
1
86064523
125
15. Remove the upper dash cover, 1, and disconnect
the throttle cable at the lever, 2 and remove the
cable from the cab. 1
2
86064793
126
90-44
16. Disconnect the external linkages to the clutch
pedals, 1.
17. Disconnect the external linkages to the forward
and reverse pedals, 2.
2
20004155
127
18. Remove the right side dash cover, not shown.
19. Remove the access cover (not shown) and
identify the P/S hoses, 1, going into the pump, 2. 1
20. Mark each hose and remove from the pump.
56064540
128
21. Remove the differential lock lever, 1, from the
cab.
86064810
129
90-45
22. Remove loader valve piping from the cab, if
equipped.
86065613
130
23. Remove the left front cab mount bolt and washer,
1.
24. Repeat procedure for right side cab mount.
86064813
131
25. Remove the left rear cab mount bolt and washer,
1.
26. Remove the right rear cab mount bolt and 2
1
washer, 2.
86064812
132
90-46
27. Prior to lifting the cab off the tractor, remove both
cab access doors as described in this section.
86064801
133
Cab Lifting Fixture
Installation
1. Install the cab lifting fixture #380002802 through
the cab door opening, with longer end of angle
iron toward the front of cab.
2. Position the lifting fixture, so that the spring
loaded pins, insert into the holes in the cab door
upper frame. These pins locate the fixture front
to back evenly so that the cab is balanced during
lifting. Tool #380002802
3. Using an overhead hoist, attach a chain to the
86066080
eyebolts of the fixture.
134
4. Lift cab slowly, check for any linkages, wire
harnesses or hoses that could be caught on the
cab, impeding the lifting of the cab from the
tractor.
86066081
135
90-47
Installation
1. Install the left front cab mount bolt and washer, 1.
2. Repeat procedure for right side cab mount.
86064813
136
3. Install the left rear cab mount bolt and washer, 1.
4. Install the right rear cab mount bolt and washer,
2. 2
1
86064812
137
5. Install both cab access doors as described in this
section.
86064801
138
90-48
6. Install the loader valve piping, if equipped.
86065613
139
7. Connect the external linkages to the clutch
pedals, 1.
8. Connect the external linkages to the forward and
reverse pedals, 2.
2
20004155
140
9. Reinstall each hose, 1, to the pump.
10. Install the access cover (not shown) for the
pump, 2. 1
11. Install the right side dash cover, not shown.
56064540
141
90-49
12. Install the differential lock lever, 1, into the cab.
86064810
142
13. Install the cable through the firewall of the cab
and connect the throttle cable at the lever, 1.
14. Install the upper dash cover, 2. 2
1
86064793
143
15. Connect the electrical harness connectors, 1, at
the cab.
10054350
144
90-50
16. Secure the ground cable, 1, on the left side of the
firewall, just above the starter.
1
86064523
145
IMPORTANT: Whenever the a/c system is open for
service, the receiver/drier must be replaced. 1
17. Replace O-rings and connect the high pressure

line going to the receiver/drier, 1.
18. Replace O-rings and connect the low pressure 2
hose going into the a/c compressor, 2.
19. See “Charging” in Section 50 of the repair
manual.
86063996
146
20. Install and secure the heater hoses, 1, to the
engine.
21. Fill the engine coolant and bleed air from the
system.
86064535
147
90-51
22. Install the fuel tank, 1, as described in this
section.
86064812
148
23. Attach rod, 1, to the HPL Drop Rate Control
Valve, 2.
3
24. Secure the rod with hair pin, 3.
86064529
149
25. Connect the linkages, 1, going to the PTO, FWD,
Height and Range levers in the cab.
26. Install and secure the fifteen bolts and washers, 2
2, which secure the fender to the cab.
27. Repeat procedure for other fender and linkages.
86064059
150
90-52
28. Install the rear wheels, 1, on the tractor. Torque
the lug bolts to 129 N⋅m (95 ft-lb).
29. Remove jack stands from under the rear axle, not
shown.
86064060
151
90-53
90-54

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D35, DX35, D40, DX40,

SECTION 25 - FWD FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 27 - DIFFERENTIAL, REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 29 - HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION 31 - POWER TAKE-OFF (PTO) SYSTEMS . . . . . . . . . . . . . . . . . . . . 21

SECTION 35 - HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SECTION 44 - 2WD FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

SECTION 50 - CLIMATE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SECTION 55 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chapter 1 - General Information

Section Description Page

Section Description Page

Chapter 1 - Engine (Continued)

Section Description Page

Chapter 1 - Engine (Continued)

Section Description Page

Chapter 1 - Engine (Continued)

Section Description Page

Chapter 1 - Engine (Continued)

Section Description Page

Chapter 1 - Engine (Continued)

Section Description Page

Chapter 2 -- Fuel Systems

Section Description Page

Chapter 2 -- Fuel Systems (Continued)

Section Description Page

Section Description Page

Chapter 1 -- Clutch (Continued)

Section Description Page

Chapter 1 - 12 x 12 Synchronized Shuttle Shift Gear Transmission

Section Description Page

Chapter 1 - 12 x 12 Synchronized Shuttle Shift Gear Transmission

Section Description Page

Chapter 1 - 12 x 12 Synchronized Shuttle Shift Gear Transmission

Section Description Page

Chapter 1 - 12 x 12 Synchronized Shuttle Shift Gear Transmission

Section Description Page

Section Description Page

Chapter 1 - FWD Front Axle

Section Description Page

Chapter 1 - FWD Front Axle (Continued)

Section Description Page

SECTION 27 - DIFFERENTIAL, REAR AXLE

Chapter 1 - Differential, Rear Axle

Section Description Page

Chapter 1 - Differential, Rear Axle (Continued)

Section Description Page

SECTION 29 -- HYDROSTATIC TRANSMISSION

Chapter 1 -- Hydrostatic Transmission

Section Description Page

Chapter 1 -- Hydrostatic Transmission (Continued)

Section Description Page

Chapter 1 -- Hydrostatic Transmission (Continued)

Section Description Page

Chapter 1 -- Hydrostatic Transmission (Continued)

Section Description Page

Section Description Page

SECTION 31 -- POWER TAKE-OFF (PTO) SYSTEMS

Chapter 1 -- Power Take-Off (PTO) Systems