John Deere Tractors 5036C, 5041C, 5042C Diagnostics and Repair Service Manual (TM901719)

tm901719 - 5036C and 5042C Tractors (Export Edition,December 2015) Technical Manual.pdf

Complete All Inclusive Technical Manual with electrical wiring diagrams for John Deere Tractors 5036C, 5041C, & 5042C (Export, PIN Prefix PY / 1PY) , with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).

John Deere Tractors 5036C, 5041C, 5042C workshop technical service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 1,323 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
  Foreword
   General Information
      Safety
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
      Features
   Engine Repair
      Engine
      Cylinder Head and Valves
      Cyl. Block, Liners, Pistons & Rods
      Crankshaft, Main Bearings and Flywheel
      Camshaft and Timing Gear Train
      Lubrication System
      Cooling System
   Fuel and Air Repair
      Fuel System
      Air Intake and Exhaust System
      Speed Control Linkage
   Electrical Repair
      Battery, Starter and Alternator
      Electrical System Components
      Wiring Harness
   Power Train Repair
      Clutch Housing
      Clutch Assembly
      Transmission
      Rear PTO Single Clutch
      Differential
      Final Drives
   Steering and Brake Repair
      Steering Repair
      Brake Repair
   Hydraulic Repair
      Hydraulic Pump and Filter
      Rockshaft
   Miscellaneous Repair
      Front Axle
      Wheels
      3-Point Hitch
      Front Bumper
   Operator Station Repair
      Seat and Support
      Operator Platform
      Fenders
      Hood
      Roll-Gard™
   Operational Checkout Procedures
      Operational Checkout Procedures
   Engine Operation, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Fuel/Air Operation, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Electrical System Operation, Tests & Adjustments
      Component Location
      Theory of Operation
      Wiring Schematics
      Diagnosis, Test and Adjust
      Component Information-Connectors
   Power Train Operation, Tests and Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Steering and Brake Operation, Tests & Adjustments
      Component Location
      Theory of Operation
      Diagnosis, Tests and Adjustments
   Hydraulic System Operation, Tests & Adjustments
      Component Location
      Theory of Operation
      Diagnosis
      Hydraulic Tests
      Adjustments - HARIG Rockshaft
      Hydraulic Schematics
   Special Tools
      Dealer Fabricated Tools

tm901719 - 5036C and 5042C Tractors (Export Edition,December 2015)

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Follow Safety Instructions

Prepare for Emergencies

Wear Protective Clothing

Protect Against Noise

Handle Fuel Safely—Avoid Fires

Handle Starting Fluid Safely

Fire Prevention

In Case of Fire

Avoid Static Electricity Risk When Refueling

Keep ROPS Installed Properly

Use Foldable ROPS and Seat Belt Properly

Stay Clear of Rotating Drivelines

Use Steps and Handholds Correctly

Read Operator’s Manuals for ISOBUS Controllers

Use Seat Belt Properly

Operating the Tractor Safely

Avoid Backover Accidents

Limited Use in Forestry Operation

Operating the Loader Tractor Safely

Keep Riders Off Machine

Instructional Seat

Use Safety Lights and Devices

Use a Safety Chain

Transport Towed Equipment at Safe Speeds

Use Caution On Slopes and Uneven Terrain

Freeing a Mired Machine

Avoid Contact with Agricultural Chemicals

Handle Agricultural Chemicals Safely

Handling Batteries Safely

Avoid Heating Near Pressurized Fluid Lines

Remove Paint Before Welding or Heating

Handle Electronic Components and Brackets Safely

Practice Safe Maintenance

Avoid Hot Exhaust

Clean Exhaust Filter Safely

Work In Ventilated Area

Support Machine Properly

Prevent Machine Runaway

Park Machine Safely

Transport Tractor Safely

Service Cooling System Safely

Service Accumulator Systems Safely

Service Tires Safely

Service Front-Wheel Drive Tractor Safely

Tightening Wheel Retaining Bolts/Nuts

Avoid High-Pressure Fluids

Do Not Open High-Pressure Fuel System

Store Attachments Safely

Decommissioning: Proper Recycling and Disposal of Fluids and Components

Group 10: General Specifications

John Deere 5036C Tractor

John Deere 5042C Tractor

Ground Speed at Rated Engine Speed (2100 rpm)

Service Recommendations for O-Ring Boss Fittings

Service Recommendations for Flat Face O-Ring Seal Fittings

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Group 15: Fuel and Lubricants

Diesel Fuel

Handling and Storing Diesel Fuel

Lubricity of Diesel Fuel

Oil Filters

Do Not Use Galvanized Containers

Fill Fuel Tank

Diesel Engine Oil — Tier 3 and Stage III

Diesel Engine Break-In Oil — Non-Emissions Certified and Certified Tier 1, Tier 2, Tier 3, Stage I, Stage II, and Stage III

Diesel Engine Coolant

Transmission and Hydraulic Oil

Grease (Specific Application)

Grease

Alternative and Synthetic Lubricants

Lubricant Storage

Group 20: Serial Number Locations

Serial Numbers

Product Identification Number Location

Engine Serial Number Location

Fuel Injection Pump Serial Number Location

Alternator Serial Number Location

Power Steering Valve Serial Number Location

Starter Serial Number Location

Transmission Serial Number Location

Front Axle Serial Number Location

Group 25: Features

Standard Features

Section 20: Engine Repair

Group 05: Engine

Service Equipment and Tools

Specifications

John Deere Engine Repair — Use CTM125

Remove Engine

Install Engine

Group 10: Cylinder Head and Valves

Special or Essential Tools

Specifications

Torques for Hardware

Cylinder Head - Exploded View

Check Valve Lift

Remove cylinder head

Clean Injection Nozzle Bores

Valve Actuating Parts

Remove Valves and Valve Springs

Checking Cylinder Head Flatness

Clean Valve Guides

Measure Valve Guides

Knurl Valve Guides

Clean and Inspect Valve Seats

Lapping Valve Seats

Check Valve Recess

Remove Valve Seat Inserts

Valve Seat Insert Installation

Check Valves

Grind Valves

Check Valve Spring Compression

Inspect Valve Rotators

Install Valves

Install Cylinder Head

Torque Turn Tightening Method

Disassembling and Checking Rocker Arm Shaft

Reassembling Rocker Arm Shaft

Install Rocker Arm Assembly

Valve Clearance

Valve Adjustment Sequence

Install Rocker Arm Cover

Final Work

Group 15: Cyl. Block, Liners, Pistons & Rods

Special or Essential Tools

Specifications

Torques for Hardware

Exploded View

Connecting Rods - General Information

Remove Pistons and Connecting Rods

Measure Cylinder Liner Bore

Remove Cylinder Liners

Cylinder Liner Deglazing

Cylinder Block Cleaning

Check Piston Cooling Jets

Cam Follower Bore Measure

Measure Camshaft Bore

Remove Camshaft Bushing

Install Camshaft Bushing

Measure Crankshaft Bore

Replace Crankshaft Bearing Caps

Cylinder Block Top Desk Flatness

Measure Cylinder Liner Protrusion

Liner Packing Installation

Liner O-Ring Installation

Install Cylinder Liners

Measure Connecting Rod Bearing

Rod Bearing Clearance

Measure Connecting Rod Bushing

Replace Connecting Rod Bushing (Straight Pin-End)

Replace Connecting Rod Bushing (Tapered Pin-End)

Measure Piston Pin

Clean and Inspect Pistons

Measure Piston Pin Bore

Piston Top Ring Groove

Second and Third Piston Ring Grooves

Piston Head and Skirt Checking

Install Piston Rings

Piston Rings Staggering

Piston/Liner Set Information

Assemble Piston and Connecting Rod

Install Piston and Connecting Rod

Measure Piston Protrusion

Complete Final Assembly

Group 20: Crankshaft, Main Bearings and Flywheel

Special or Essential Tools

Specifications

Torques for Hardware

Remove Crankshaft Pulley

Install Crankshaft Pulley

Flywheel Removal

Flywheel Ring Gear Replacement

Install Ball Bearing

Install Flywheel

Remove Crankshaft Rear Oil Seal

Flywheel Housing Replacement

Install Oil Seal/Wear Sleeve

Crankshaft End Play Measure

Remove Crankshaft

Crankshaft Inspection

Crankshaft Identification

Check Crankshaft Journal Diameter

Determine Crankshaft Main Bearing Clearance Using PLASTIGAGE PLASTIGAGE is a trademark of DANA Corp.

Regrind Crankshaft

Crankshaft Regrinding Guidelines

Micro-Finishing Specifications

Replace Crankshaft Gear

Install Main Bearing Inserts

Install 2-Piece Thrust Bearing

Crankshaft Installation

Group 25: Camshaft and Timing Gear Train

Special or Essential Tools

Specifications

Torques for Hardware

Remove Crankshaft Front Oil Seal

Remove Timing Gear Cover

Remove Oil Deflector

Measure Timing Gear Backlash

Camshaft End Play Measure

Remove Camshaft

Measure Camshaft Journal

Measure Height of Cam Lobe

Replace Camshaft Gear

Install Camshaft

Check Cam Follower

Idler Gear End Play Measure

Remove Front Plate

Idler Gear Bushing and Shaft Measure

Idler Gear Bushing Replacement

Remove Idler Shaft

Install Idler Shaft Spring Pin

Install Idler Shafts

Install Front Plate

Install Upper Timing Gear Train

Install Lower Timing Gear Train

Install Oil Deflector

Timing Gear Cover Identification

Install Timing Gear Cover

Install Crankshaft Front Oil Seal

Install Wear Ring

Install Auxiliary Equipment

Group 30: Lubrication System

Special or Essential Tools

Specifications

Torques for Hardware

Remove Oil Pressure Regulating Valve

Replace Oil Pressure Regulating Valve Seat

Install Oil Pressure Regulating Valve

Replace Oil Dipstick Guide

Remove Oil Pan

Replace Oil By-Pass Valve

Replace Oil Pump Strainer

Remove Oil Pump

Oil Pump Gear Axial Clearance

Oil Pump Gear Radial Clearance

Oil Pump Specifications

Oil Pump - Exploded View

Oil Pump Installation

Install Oil Pan

Group 35: Cooling System

Special or Essential Tools

Torques for Hardware

Remove and Inspect Radiator

Remove Fan

Remove Water Pump

Disassemble Water Pump

Water Pump — Exploded View

Assemble Water Pump

Install Water Pump

Inspect Thermostat

Cooling System Deaeration

Check Fan/Alternator Belt Tension

Install Fan

Install Radiator

Replace Thermostat

Section 30: Fuel and Air Repair

Group 05: Fuel System

Special or Essential Tools

Self-Manufactured Tool Template for Front Plate Replacement

Specifications

Torques For Hardware

Injection Pump, Nozzle and Governor Repair — Use CTM125

Remove, Inspect and Install Fuel Tank

Replace Fuel Filter

Remove and Install Fuel Filter Assembly

Group 10: Air Intake and Exhaust System

Remove, Inspect, and Install Air Cleaner Elements

Check Air Inlet Pipe

Exhaust Manifold Inspection

Group 15: Speed Control Linkage

Inspect and Repair Speed Control Linkage

Section 40: Electrical Repair

Group 05: Battery, Starter and Alternator

Specification

Starter Repair—Use CTM77

Remove and Install Battery

Remove and Install Starter

Replace Alternator/Regulator

Group 10: Electrical System Components

Service Equipment and Tools

Other Material

Specifications

Replace Air Filter Restriction Sensor

Replace Coolant Temperature Sender

Replace Engine Oil Pressure Sensor

Replace Key Switch

Replace Light Switch

Replace Turn Signal Controller and Hazard Switch

Replace Mobile Charger Switch

Replace Horn Switch

Replace Instrument Panel

Disassemble, Inspect and Assemble Instrument Cluster

Replace Neutral Start Switch

Replace Brake Switch

Replace Fuel Level Sender

Replace 7 Pin Connector

Replace PTO Switch

Group 15: Wiring Harness

Special or Essential Tools

Service Parts Kits

Remove Connector Body from Blade Terminals

Replace Tractor Wiring Harnesses

Battery Wiring Harness

Hood Wiring Harness

Rear Wiring Harness

Front Wiring Harness

Section 50: Power Train Repair

Group 05: Clutch Housing

Service Equipment and Special Tools

Other Material

Specifications

Separate Engine from Transmission Housing

Install Engine to Transmission Housing

Inspect and Repair Clutch Pedal and Linkage

Group 10: Clutch Assembly

Other Material

Special Tools

Specifications

Remove and Install Single Clutch Assembly

Remove and Inspect Single Clutch Release Mechanism and Shaft

Install Single Clutch Release Mechanism and Shaft

Group 20: Transmission

Other Material

Specifications

Special Tools

Remove, Inspect and Repair Gear and Reverse Shift Lever And Cover

Remove, Inspect and Install Range Shift Lever

Remove Clutch Housing from Transmission Housing

Disassemble and Inspect Transmission

Disassemble, Inspect and Assemble Shift Shaft Assemblies

Disassemble and Inspect Top Shaft

Assemble Top Shaft

Disassemble and Inspect Differential Drive Shaft

Assemble Differential Drive Shaft

Disassemble and Inspect Reverse Idler Shaft

Assemble Reverse Idler Shaft

Disassemble and Inspect Clutch Drive Shaft

Assemble Clutch Drive Shaft

Assemble Transmission

Install Clutch Housing to Transmission Housing

Group 30: Rear PTO Single Clutch

Specifications

Special Tools

Remove, Inspect and Install Rear PTO Lever and Linkage

Remove and Install Rear PTO Drive Shaft Assembly

Disassemble, Inspect and Assemble Rear PTO Driven Shaft and Shifter Assembly

Group 35: Differential

Special Tools

Other Material

Specifications

Remove and Install Differential Assembly

Disassemble, Inspect and Assemble 2-Pinion Differential Assembly

Differential Cone Point Adjustment for 2-Pinion Differential

Differential Backlash Adjustment

Group 40: Final Drives

Other Material

Specifications

Special Tools

Remove and Install Final Drive Assembly

Remove and Inspect Rear Drive Assembly

Install Rear Drive Assembly

Remove and Inspect Rear Axle Shaft Assembly

Install Rear Axle Shaft Assembly

Section 60: Steering and Brake Repair

Group 05: Steering Repair

Special Tools

Other Material

Specifications

Service Parts Kits

Remove and Install Steering Wheel

Remove and Install Steering Column and Valve

Disassemble and Inspect Steering Valve

Assemble Steering Valve

Remove and Install Steering Cylinder

Disassemble, Inspect and Assemble Steering Cylinder

Remove, Inspect and Install Tie Rod Assembly

Inspect and Replace Steering Hydraulic Lines

Specifications—Mechanical Steering

Remove Mechanical Steering Assembly

Disassemble Steering Gearbox

Inspect Steering Gearbox Parts

Assemble Steering Gearbox

Install Mechanical Steering Assembly

Group 10: Brake Repair

Special Tools

Other Material

Specifications

Remove and Install Brake Pedals and Linkage

Remove and Install Park Brake Lever and Linkage

Remove and Inspect Brakes

Install Brakes

Section 70: Hydraulic Repair

Group 05: Hydraulic Pump and Filter

Special Tools

Specifications

Service Parts Kits

Remove, Inspect, and Install Hydraulic Oil Strainer

Remove and Install Hydraulic Pump

Remove Hydraulic Pump External Components

Disassemble and Inspect Hydraulic Pump

Assemble Hydraulic Pump

Install Hydraulic Pump External Components

Remove and Install Hydraulic Oil Filter/Manifold

Inspect and Replace Hydraulic Supply and Suction/Return Lines

Group 10: Rockshaft

Other Material

Specifications

Remove and Install Rockshaft Case

Remove, Inspect, and Install Rockshaft Control Lever Assembly

Remove, Inspect, and Install Rockshaft Control Lever Support Assembly

Replace Pressure Relief Valve

Remove, Inspect and Install Rate-of-Drop valve

Remove, Inspect and Replace Rockshaft Control valve

Remove, Inspect, and Install Rockshaft Lift Arms

Remove, Inspect, and Install Rockshaft Piston and Cylinder

Remove, Inspect and Install Rockshaft Control Linkage

Remove, Inspect and Install Rockshaft Spring Housing Assembly

Section 80: Miscellaneous Repair

Group 05: Front Axle

Specifications

Remove and Install Front Axle

Inspect and Replace Seals and Bushings

Remove and Install Spindle Assembly

Inspect and Replace Spindle Shaft Bushings (Fixed Front Axle)

Inspect and Replace Spindle Shaft Bushings (Adjustable Front Axle)

Group 10: Wheels

Specifications

Remove and Install Front or Rear Wheels

Inspect and Replace Front Wheel Bearings

Tighten Bolts—Rear Axle (M-16 Stud)

Replace SMV Emblem

Group 15: 3-Point Hitch

Specifications

Inspect and Repair Fixed Draft Links

Inspect and Repair Adjustable Lift Link

Inspect and Repair Fixed Lift Link

Inspect and Repair Center Link

Remove and Install Wagon Hitch and Support

Group 20: Front Bumper

Replace Front Bumper

Section 90: Operator Station Repair

Group 05: Seat and Support

Specifications

Remove and Install Seat and Support

Group 10: Operator Platform

Specifications

Remove and Install Right-Side Platform

Remove and Install Left-Hand Side Platform and Step

Group 15: Fenders

Specification

Remove and Install Fenders

Group 20: Hood

Remove, Inspect and Install Hood

Remove and Install Cowl Assembly

Group 25: Roll-Gard™

Roll-Gard™—Summary of References

Specifications

Remove and Install Roll-Gard™

Section 210: Operational Checkout Procedures

Group 05: Operational Checkout Procedures

Operational Checkout Procedure Information

Engine Oil Level and Condition Check

Coolant Level and Condition Check

Transmission and Hydraulic Oil Check

Fan and Belt Check

Fuel System Check

Air Intake System Check

Electrical System Check

Hydraulic System Check

Indicator Lamps Check

Engine Start Check

Transmission Neutral Start Check

Engine Fast and Slow Idle Operation

Power Steering Check

Clutch Check

Speed Lever Shift Check

Range Lever Shift Check

Brake Check

Rockshaft Check

Miscellaneous Checks

Section 220: Engine Operation, Tests and Adjustments

Group 10: Component Location

Component Location Information

Engine External Components—Left-Hand Side

Engine External Components—Right-Hand Side

Group 15: Theory of Operation

Theory of Operation Information

Engine Lubrication System Operation

Engine Cooling System Operation

Group 20: Diagnosis, Tests and Adjustments

Specifications

Special Tools

Diagnostic Information

Engine Turns Over But Will Not Start or Starts Hard

Engine Runs Irregularly or Stalls Frequently

Engine Runs Rough

Engine Low Power

Engine Smokes—Black or Grey

Engine Smokes Excessively—White

Engine Uses Excess Fuel

Engine Has Excess Noise or Vibration

Engine Uses Excess Oil or Smokes Blue

Engine Has Low Oil Pressure

Engine Coolant Operating Temperature Incorrect

Oil In Coolant or Coolant in Oil

Radiator Bubble Test

Cooling System Test

Radiator Cap Pressure Test

Engine Oil Pressure Test

Cylinder Compression Pressure Test

Throttle Lever Adjustment

Fuel Injection Pump Setting

Idle Speed Adjustment

Valve Clearance Adjustment

Fan/Alternator Drive Belt Adjustment

Bleed Fuel System

Bleed Fuel System At Fuel Injection Nozzles

Section 230: Fuel/Air Operation, Tests and Adjustments

Group 05: Component Location

Component Location Information

Fuel System Components

Air Intake System Components

Group 10: Theory of Operation

Theory of Operation Information

Fuel System Operation

Fuel Filter Pump Operation

Fuel Injection Nozzle Operation

Fuel Transfer (Feed) Pump Operation

In-Line Fuel Injection Pump Operation

Governor Operation (In-Line Pump)

Air Intake System Operation

Group 15: Diagnosis, Tests and Adjustments

Diagnostic Information

Fuel/Air Diagnosis, Tests and Adjustments

Section 240: Electrical System Operation, Tests & Adjustments

Group 05: Component Location

Component Location Information

Engine Electrical Components—Right Hand Side

Engine Electrical Components—Left Hand Side

Tractor Electrical Components

Group 10: Theory of Operation

Theory of Operation Information

Fuse Block and Fuses

Starting System Operation

Charging System Operation

Lighting System Operation—Turn Signals

Lighting System Operation—Hazard Warning Lights

Lighting System Operation—Tail Lights

Lighting System Operation—Front Position Lights

Lighting System Operation—Headlights

Instrument Panel System Operation—Illumination

Instrument Panel System Operation—Tachometer/Hour Meter

Instrument Panel System Operation—Temperature Gauge

Instrument Panel System Operation—Fuel Gauge

Instrument Panel System Operation—Engine Oil Pressure

7-Pin Trailer Connector Operation

Horn Operation

Mobile Charger Operation

Brake Operation

Flood Light Operation

Group 15: Wiring Schematics

Schematic Information

Component Identification Table

Electrical Schematic

Group 20: Diagnosis, Test and Adjust

Diagnostic Information

Starting System Test Points—Normal Operation

Charging System Test Points

Lighting System Test Points—Turn Signals

Lighting System Test Points—Hazard Warning Lights

Lighting System Test Points—Tail Lights

Lighting System Test Points—Front Position Lights

Lighting System Test Points—Head Lights

Instrument Panel Test—Illumination

Instrument Panel Test—Tachometer/Hour Meter

Instrument Panel Test—Temperature Gauge

Instrument Panel Test—Fuel Gauge

Instrument Panel Test—Engine Oil Pressure Gauge

7-Pin Connector Test Points

Horn Test Points

Mobile Charger Test Points

Brake Lights Test Points

Flood Light Test Points

Battery Voltage and Specific Gravity Tests

Charge Battery

Battery Load Test

Starter AMP Draw/RPM Test

Starter No-Load AMP Draw/RPM Test

Alternator/Regulator Test

Starter Solenoid Test

Fuse Test

Neutral Start Switch Test

PTO Switch Test

Turn Signal Controller (Flasher) Test

Group 25: Component Information—Connectors

X1—8 Pin Connector for Rear Wiring Harness

X2—16 Pin Connector for Instrument Cluster

X3—4 Pin Connector for Hood Harness

X11—4 Pin Connector for Front Harness

X12—2 Pin Connector for Maxi Fuse (+40 A)

X4—4 Pin Connector for Right-Hand Side Fender

X5—7 Pin Connector for Trailer Connection

X6—4 Pin Connector for Left-Hand Side Fender

X7—8 Pin Connector for Front Wiring Harness

X9—3 Pin Connector for Right-Hand Front Position and Turn Lights

X10—3 Pin Connector for Left-Hand Front Position and Turn Lights

XB1 I—1 Pin Connector for Horn

XB1 II—1 Pin Connector for Horn

XB2—1 Pin Connector for Coolant Temperature Sender

XB3—2 Pin Connector for Fuel Level Sender

XB4—1 Pin Connector for Engine Oil Pressure Sensor

XE01—2 Pin Connector for Flood Light

XE02—3 Pin Connector for High/Low Left-Hand Head Light

XE03—3 Pin Connector for High/Low Right-Hand Head Light

XF00—12 Pin Connector for Fuse Box

XG2 I—2 Pin Connector for Alternator

XG2 II—1 Pin Connector for Alternator

XG2 III—1 Pin Connector for Alternator

XGND01—1 Pin Connector for Ground

XK1—3 Pin Connector for Flasher

XK1 II—1 Pin Connector for Flasher

XM1 I—1 Pin Connector for Starter

XM1 II—1 Pin Connector for Starter

XM1 III—1 Pin Connector for Starter (Ground)

XR1 I—1 Pin Connector for Mobile Charger

XR1 II—1 Pin Connector for Mobile Charger

XS1 I—1 Pin Connector for Key Switch

XS1 II—1 Pin Connector for Key Switch

XS1 III—1 Pin Connector for Key Switch

XS2—2 Pin Connector for Neutral Start Switch

XS3 I—1 Pin Connector for Horn Switch

XS3 II—1 Pin Connector for Horn Switch

XS5—4 Pin Connector for Light Switch

XS6 I—1 Pin Connector for Brake

XS6 II—1 Pin Connector for Brake

XS7 I—1 Pin Connector for Left-Hand Turn Switch

XS7 II—1 Pin Connector for Right-Hand Turn Switch

XS8—2 Pin Connector for PTO Switch

Section 250: Power Train Operation, Tests and Adjustments

Group 10: Component Location

Component Location Information

Power Train Components

Clutch Components

Transmission Components

Final Drive Components

Rear PTO Components

Group 20: Theory of Operation

Theory of Operation Information

Single Clutch Operation

Transmission Lubrication System (Manual Steering Tractor)

Transmission Lubrication System (Power Steering Tractor)

Transmission Lubrication System (Without Rockshaft Tractor)

Transmission Power Flow—Forward Drive (A Range)

Transmission Power Flow—Forward Drive (B Range)

Transmission Power Flow—Reverse Drive

Rear PTO Operation

Differential Power Flow

Final Drive Operation

Group 25: Diagnosis, Tests and Adjustments

Diagnostic Information

Isolate the Problem Area

Traction Clutch Slips

Traction Clutch Dragging

Traction Clutch Does Not Engage

Traction Clutch Grabs

Traction Clutch Squeaks

Traction Clutch Does Not Release

Traction Clutch Chatters

Traction Clutch Rattles

Traction Clutch Engagement Is Noisy

Excessive Vibration in Traction Clutch

Clutch Pedal Does Not Return

Clutch Pedal Loose

Clutch Pedal Pulsates

Jerky or Rough Transmission of Power

Low Transmission Oil Level (Excessive Oil Leakage or Seepage)

Gears Clash, Shifts Hard, or Will Not Engage

Transmission Will Not Stay in Gear

Transmission Noisy

PTO Noisy

PTO Hard to Engage

PTO Will Not Operate

PTO Will Not Stay Engaged

Excessive Differential Noise

Differential Does Not Work

Differential Chatters

Axle Noise

Axle Shaft Will Not Turn

Clutch Pedal Free Play Adjustment

Section 260: Steering and Brake Operation, Tests & Adjustments

Group 05: Component Location

Component Location Information

Steering System Components (Power Steering)

Steering System Components (Mechanical Steering)

Brake System Components

Group 10: Theory of Operation

Theory of Operation Information

Steering System Operation (Power Steering)

Steering System Operation (Mechanical Steering)

Steering Valve Operation—Neutral and Manual Turning

Steering Valve Operation—Power Turning

Brake System Operation

Group 15: Diagnosis, Tests and Adjustments

Specifications

Diagnostic Information

Isolate the Problem—Steering System

Steering Sluggish or Loss of Steering

Steering Pump Flow Test

Steering Valve Relief Test

Steering Cylinder Leakage Test

Steering Valve Leakage Test

Steering Wheel Free Play - Adjustment

Toe-In Check and Adjustment—Standard Axle

Isolate the Problem—Brakes

Brake Pedal Adjustment

Park Brake Lever Adjustment

Section 270: Hydraulic System Operation, Tests & Adjustments

Group 05: Component Location

Component Location Information

Hydraulic System Components—Manual Steering

Hydraulic System Components—Power Steering

Hydraulic System Components—Without Rockshaft

Group 10: Theory of Operation

Theory of Operation Information

Hydraulic Filter Operation

Hydraulic Pump Operation

Hydraulic System Operation—Manual Steering

Hydraulic System Operation—Power Steering

Hydraulic System Operation—Without Rockshaft

Rockshaft Control Valve Operation—Neutral Phase

Rockshaft Control Operation—Lift Phase

Rockshaft Control—Lower Phase

Group 15: Diagnosis

Diagnostic Information

Preliminary Hydraulic System Inspection

Entire Hydraulic System Fails to Function/No Hydraulic Pump Output

Insufficient Pump Delivery

Hydraulic Functions Too Slow

Excessive Pump Pressure

Slow Hydraulic Pump Response

Excessive Pump Noise During Operation

Rockshaft Jerking in Lift Position

Rockshaft Does Not Lift or Lifts Slowly

Rockshaft Does Not Lower or Lowers Slowly

Rockshaft Lowering Automatically

Draft Sensing Not Working During Application

Position or Draft Control Lever too Hard or Loose

External Hydraulic Connection Not Working

Tipping Trolley Not Coming Down

Insufficient Maximum Lift of Implement

Rockshaft Over Heating

Lift Capacity Does Not Correspond as Recommended

Rockshaft too Responsive

Group 20: Hydraulic Tests

Hydraulic System Tests

Pump Flow Test

Main Relief Valve Test

Rockshaft Leakage Test

Rockshaft Lift Cycle Test

Group 25: Adjustments - HARIG Rockshaft

Rockshaft Sensing Lever Friction Adjustment

Group 30: Hydraulic Schematics

Hydraulic Circuit Symbols

Hydraulic Schematics

Section 280: Special Tools

Group 05: Dealer Fabricated Tools

DF001 - Guide Pin

DF002 - Clutch Housing Plug Installer

DF003 - PTO Plug Installer

DF004 - Brake Shaft Bush Installer