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New holland t9030 series tractor service repair manual

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This document provides a master table of contents for service manuals covering TJ and T9000 tractors. It lists sections for topics like standard torque specifications, safety, lubrication and maintenance procedures, specifications for engine and other systems, and procedures for removing and installing engines on various tractor models. Engine repair information is provided in separate manuals referenced by part number.

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TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 1 THIS MANUAL, 84257310, COVERS THE FOLLOWING TRACTORS: TJ 280, 330, 380, 430, 480, and 530 Series T9010, 9020, 9030, 9040, 9050, and 9060 Series T9020, 9030, 9040, 9050, and 9060 Series After S/N Z7F204001 NOTE: Engine repair information is not contained within this tractor Service Manual. For engine repair, refer to appropriate engine service manual as follows: 87515682 - For 8.3 & 9.0L 6 Cylinder, 24 Valve CNH Engine with High Pressure Common Rail Fuel System. 87523643 - For 12.9L 6 Cylinder, Engine. 87737594 - For 12.9L 6 Cylinder, Turbo Compound Engine. STANDARD TORQUE SPECIFICATION.......................................SECTION 00, CHAPTER 1 (Book 1 - 87525642) SAFETY..........................................................................................SECTION 00, CHAPTER 2 (Book 1 - 87525642) LUBRICATION AND MAINTENANCE............................................SECTION 00, CHAPTER 3 (Book 1 - 87525642) ENGINE LUBRICATION ............................................................................................................................. 00-3-3 Engine Oil Selection .................................................................................................................................. 00-3-3 Synthetic Lubricants .................................................................................................................................. 00-3-3 Engine Oil Viscosity/Temperature Usage Recommendation .................................................................... 00-3-3 Engine Coolant Solutions .......................................................................................................................... 00-3-4 LUBRICANTS AND CAPACITIES .............................................................................................................. 00-3-5 LUBRICATION AND MAINTENANCE CHART ........................................................................................... 00-3-6 SPECIFICATIONS..........................................................................SECTION 00, CHAPTER 4 (Book 1 - 87525642) DIESEL ENGINE ........................................................................................................................................ 00-4-3 ENGINE LUBRICATION SYSTEM ............................................................................................................. 00-4-3 FUEL SYSTEM ........................................................................................................................................... 00-4-3 AIR INTAKE SYSTEM ................................................................................................................................ 00-4-3 TRANSMISSION - POWER SHIFT ............................................................................................................ 00-4-4 TRANSMISSION - MANUAL SHIFT ........................................................................................................... 00-4-4 BRAKES ..................................................................................................................................................... 00-4-4 AXLE DIFFERENTIAL AAND FINAL DRIVES ............................................................................................ 00-4-4 POWER TAKEOFF (IF EQUIPPED) ........................................................................................................... 00-4-4 HYDRAULIC SYSTEM ............................................................................................................................... 00-4-5 MEGAFLOW HYDRAULICS (IF EQUIPPED) ............................................................................................. 00-4-5 HITCH SYSTEM (IF EQUIPPED) ............................................................................................................... 00-4-5 DRAWBAR .................................................................................................................................................. 00-4-5 TRACTOR WEIGHTS ................................................................................................................................. 00-4-6 Approximate Base Shipping Weights ........................................................................................................ 00-4-6 Approximate Component Weights ............................................................................................................ 00-4-6 MAXIMUM TRACTOR OPERATING WEIGHT ........................................................................................... 00-4-6 ENGINE REMOVAL AND INSTALLATION - TJ380/430 TRACTORS..................................................................SECTION 10, CHAPTER 1 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-1-3 RECOMMENDED TOOLS .......................................................................................................................... 10-1-3 ENGINE REMOVAL .................................................................................................................................... 10-1-4 ENGINE INSTALLATION .......................................................................................................................... 10-1-13
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 2 ENGINE REMOVAL AND INSTALLATION - TJ280/330 TRACTORS..................................................................SECTION 10, CHAPTER 2 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-2-2 SPECIAL TOOLS ........................................................................................................................................ 10-2-2 ENGINE REMOVAL ................................................................................................................................... 10-2-3 ENGINE INSTALLATION ......................................................................................................................... 10-2-10 ENGINE REMOVAL AND INSTALLATION - TJ480/530 TRACTORS..................................................................SECTION 10, CHAPTER 3 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-3-2 RECOMMENDED TOOLS .......................................................................................................................... 10-3-2 ENGINE REMOVAL .................................................................................................................................... 10-3-3 ENGINE INSTALLATION .......................................................................................................................... 10-3-13 AIR INDUCTION SYSTEM - TJ380/430 TRACTORS....................SECTION 10, CHAPTER 4 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-4-2 AIR INDUCTION SYSTEM ......................................................................................................................... 10-4-3 AIR INDUCTION SYSTEM DESCRIPTION ................................................................................................ 10-4-4 AIR INDUCTION SYSTEM ......................................................................................................................... 10-4-4 AIR FILTER ELEMENTS ............................................................................................................................ 10-4-4 PRIMARY AND SECONDARY FILTER ELEMENT REMOVAL ............................................................... 10-4-5 PRIMARY FILTER ELEMENT SERVICE .................................................................................................. 10-4-7 RESTRICTION INDICATOR SWITCH REMOVAL AND TEST .................................................................. 10-4-8 AIR CLEANER HOUSING REMOVAL ........................................................................................................ 10-4-9 ASPIRATOR STRATA TUBE CLEANING ............................................................................................... 10-4-10 ASPIRATOR SAFETY CHECK VALVE REMOVAL AND TEST ............................................................... 10-4-11 ASPIRATOR SAFETY VALVE INSTALLATION ....................................................................................... 10-4-11 AIR CLEANER HOUSING INSTALLATION .............................................................................................. 10-4-12 RESTRICTION INDICATOR SWITCH INSTALLATION ........................................................................... 10-4-13 SECONDARY AND PRIMARY FILTER ELEMENT INSTALLATION ....................................................... 10-4-13 AIR INDUCTION SYSTEM - TJ280/330 TRACTORS....................SECTION 10, CHAPTER 5 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-5-3 AIR INDUCTION SYSTEM ........................................................................................................................ 10-5-4 AIR FILTER ELEMENTS ............................................................................................................................ 10-5-4 ENGINE AIR INDUCTION SYSTEM .......................................................................................................... 10-5-5 Primary And Secondary Filter Element Removal ...................................................................................... 10-5-5 PRIMARY FILTER ELEMENT SERVICE ................................................................................................... 10-5-7 RESTRICTION INDICATOR SWITCH REMOVAL AND TEST .................................................................. 10-5-7 AIR CLEANER HOUSING REMOVAL ........................................................................................................ 10-5-8 Aspirator Strata Tube Cleaning ............................................................................................................... 10-5-10 ASPIRATOR SAFETY CHECK VALVE REMOVAL AND TEST ............................................................. 10-5-12 ASPIRATOR SAFETY CHECK VALVE INSTALLATION ......................................................................... 10-5-13 AIR CLEANER HOUSING INSTALLATION .............................................................................................. 10-5-14 RESTRICTION INDICATOR SWITCH INSTALLATION ........................................................................... 10-5-15 SECONDARY AND PRIMARY FILTER ELEMENT INSTALLATION ....................................................... 10-5-16 AIR INDUCTION SYSTEM - TJ480/530 TRACTORS....................SECTION 10, CHAPTER 6 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-6-2 AIR INDUCTION SYSTEM ......................................................................................................................... 10-6-3 AIR FILTER ELEMENTS ............................................................................................................................ 10-6-4 Primary And Secondary Filter Element Removal ...................................................................................... 10-6-5 PRIMARY FILTER ELEMENT SERVICE ................................................................................................... 10-6-7 RESTRICTION INDICATOR SWITCH REMOVAL AND TEST .................................................................. 10-6-8 AIR CLEANER HOUSING REMOVAL ........................................................................................................ 10-6-9 ASPIRATOR STRATA TUBE CLEANING ............................................................................................... 10-6-10 ASPIRATOR SAFETY CHECK VALVE REMOVAL AND TEST ............................................................... 10-6-11
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 3 ASPIRATOR SAFETY VALVE INSTALLATION ....................................................................................... 10-6-11 AIR CLEANER HOUSING INSTALLATION .............................................................................................. 10-6-12 RESTRICTION INDICATOR SWITCH INSTALLATION ........................................................................... 10-6-13 SECONDARY AND PRIMARY FILTER ELEMENT INSTALLATION ....................................................... 10-6-13 VISCOUS FAN DRIVE - TJ280/330/380/430, HYD FAN DRIVE TEST - TJ480/530 .............................................SECTION 10, CHAPTER 7 (Book 1 - 87525642) VISCOUS FAN DRIVE TEST - TJ280, TJ330, TJ380, TJ430 .................................................................... 10-7-3 HYDRAULIC FAN DRIVE TEST - TJ480, TJ530 ........................................................................................ 10-7-5 RADIATOR, COOLERS AND CONDENSER REMOVE/INSTALL - TJ280/330 ....................................................SECTION 10, CHAPTER 8 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-8-2 GENERAL INFORMATION ........................................................................................................................ 10-8-3 FUEL COOLER REMOVAL ........................................................................................................................ 10-8-3 FUEL COOLER INSTALLATION ................................................................................................................ 10-8-4 ENGINE AIR TO AIR COOLER REMOVAL .............................................................................................. 10-8-6 AIR TO AIR COOLER INSTALLATION ...................................................................................................... 10-8-9 A/C CONDENSER REMOVAL ................................................................................................................ 10-8-12 A/C CONDENSER INSTALLATION ........................................................................................................ 10-8-13 HYDRAULIC/TRANSMISSION OIL COOLER REMOVAL ..................................................................... 10-8-15 HYDRAULIC/TRANSMISSION OIL COOLER INSTALLATION ............................................................... 10-8-17 RADIATOR AND COOLER ASSEMBLY REMOVAL ............................................................................... 10-8-20 RADIATOR AND COOLER ASSEMBLY INSTALLATION ........................................................................ 10-8-27 RADIATOR, COOLERS AND CONDENSER REMOVE/INSTALL - TJ480/530 ....................................................SECTION 10, CHAPTER 9 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-9-3 GENERAL INFORMATION ......................................................................................................................... 10-9-3 FUEL COOLER REMOVAL ........................................................................................................................ 10-9-4 FUEL COOLER INSTALLATION ................................................................................................................ 10-9-4 ENGINE AIR TO AIR COOLER REMOVAL ............................................................................................... 10-9-5 ENGINE AIR TO AIR COOLER INSTALLATION ....................................................................................... 10-9-7 A/C CONDENSER AND HYDRAULIC FAN COOLER REMOVAL ............................................................. 10-9-9 A/C CONDENSER AND HYDRAULIC FAN COOLER INSTALLATION ................................................... 10-9-10 RADIATOR AND COOLER ASSEMBLY REMOVAL ................................................................................ 10-9-12 RADIATOR/COOLER DISASSEMBLY ..................................................................................................... 10-9-19 RADIATOR, COOLERS AND CONDENSER REMOVE/INSTALL - TJ380/430 ..................................................SECTION 10, CHAPTER 10 (Book 1 - 87525642) SPECIAL TORQUE VALUES ................................................................................................................... 10-10-2 GENERAL INFORMATION ...................................................................................................................... 10-10-3 ENGINE AIR TO AIR COOLER REMOVAL ............................................................................................ 10-10-4 AIR TO AIR COOLER INSTALLATION .................................................................................................... 10-10-6 A/C CONDENSER REMOVAL ................................................................................................................ 10-10-7 A/C CONDENSER INSTALLATION ........................................................................................................ 10-10-8 HYDRAULIC/TRANSMISSION OIL COOLER REMOVAL ................................................................... 10-10-10 HYDRAULIC/TRANSMISSION OIL COOLER INSTALLATION ............................................................. 10-10-12 RADIATOR AND COOLER ASSEMBLY REMOVAL ............................................................................. 10-10-15
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 4 AIR INDUCTION SYSTEM, T9030, 9040 and 9050 Tractors, S/N Z7F204001 and After.......................................................... SECTION 10, CHAPTER 11 (Book 1A - 87740915) SPECIAL TORQUE VALUES ................................................................................................................... 10-11-2 AIR INDUCTION SYSTEM ....................................................................................................................... 10-11-3 AIR INDUCTION SYSTEM DESCRIPTION .............................................................................................. 10-11-4 AIR INDUCTION SYSTEM ....................................................................................................................... 10-11-4 AIR FILTER ELEMENTS .......................................................................................................................... 10-11-4 PRIMARY AND SECONDARY FILTER ELEMENT REMOVAL ............................................................. 10-11-5 PRIMARY FILTER ELEMENT SERVICE ................................................................................................ 10-11-7 RESTRICTION INDICATOR SWITCH REMOVAL AND TEST ................................................................ 10-11-8 AIR CLEANER HOUSING REMOVAL ...................................................................................................... 10-11-9 ASPIRATOR STRATA TUBE CLEANING ............................................................................................. 10-11-11 ASPIRATOR SAFETY CHECK VALVE REMOVAL AND TEST ............................................................. 10-11-12 ASPIRATOR SAFETY VALVE INSTALLATION ..................................................................................... 10-11-12 AIR CLEANER HOUSING INSTALLATION ............................................................................................ 10-11-13 RESTRICTION INDICATOR SWITCH INSTALLATION ......................................................................... 10-11-14 SECONDARY AND PRIMARY FILTER ELEMENT INSTALLATION ..................................................... 10-11-15 ENGINE REMOVAL AND INSTALLATION, T9050 TRACTOR, S/N Z7F204001 AND AFTER ..................... SECTION 10, CHAPTER 12 (Book 1A - 87740915) SPECIAL TORQUE VALUES ................................................................................................................... 10-12-3 RECOMMENDED TOOLS ........................................................................................................................ 10-12-3 ENGINE REMOVAL .................................................................................................................................. 10-12-4 ENGINE INSTALLATION ........................................................................................................................ 10-12-15 RADIATOR, COOLERS AND CONDENSER REMOVE AND INSTALL, T9050 TRACTOR ............................ SECTION 10, CHAPTER 13 (Book 1A - 87740915) SPECIAL TORQUE VALUES ................................................................................................................... 10-13-3 ENGINE AIR TO AIR COOLER REMOVAL ............................................................................................. 10-13-4 ENGINE AIR TO AIR COOLER INSTALLATION ..................................................................................... 10-13-6 A/C CONDENSER AND HYDRAULIC FAN COOLER REMOVAL ........................................................... 10-13-8 A/C CONDENSER AND HYDRAULIC FAN COOLER INSTALLATION ................................................... 10-13-9 RADIATOR AND COOLER ASSEMBLY REMOVAL .............................................................................. 10-13-11 RADIATOR/COOLER DISASSEMBLY ................................................................................................... 10-13-18 POWERSHIFT TRANSMISSION REMOVE/INSTALL - TJ280/330.......................................................................................SECTION 21, CHAPTER 1 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-1-2 SPECIAL TOOLS ........................................................................................................................................ 21-1-2 TRANSMISSION REMOVAL ..................................................................................................................... 21-1-3 TRANSMISSION INSTALLATION ............................................................................................................. 21-1-9 POWERSHIFT TRANSMISSION REMOVE/INSTALL - TJ380/430/480/530.........................................................................SECTION 21, CHAPTER 2 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-2-3 SPECIAL TOOLS ........................................................................................................................................ 21-2-3 TRANSMISSION REMOVAL ..................................................................................................................... 21-2-4 TRANSMISSION INSTALLATION ........................................................................................................... 21-2-10 ENGINE/TRANSMISSION DRIVE COUPLER REMOVE/INSTALL - TJ280/330 ....................................................SECTION 21, CHAPTER 3 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-3-2 DRIVE COUPLER REMOVAL .................................................................................................................... 21-3-3 DRIVE COUPLER INSTALLATION ............................................................................................................ 21-3-5
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 5 ENGINE/TRANSMISSION DRIVE COUPLER REMOVE/INSTALL - TJ480/530 ....................................................SECTION 21, CHAPTER 4 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-4-2 DRIVE COUPLER REMOVAL ................................................................................................................... 21-4-3 DRIVE COUPLER INSTALLATION ............................................................................................................ 21-4-6 16 SPEED POWERSHIFT TRANSMISSION REPAIR...................SECTION 21, CHAPTER 5 (Book 2 - 87525640) SPECIFICATIONS ...................................................................................................................................... 21-5-3 SPECIAL TORQUE VALUES ..................................................................................................................... 21-5-3 SPECIAL TOOLS ........................................................................................................................................ 21-5-4 TRANSMISSION DISASSEMBLY .............................................................................................................. 21-5-7 INPUT (FIRST) SHAFT DISASSEMBLY .................................................................................................. 21-5-18 PUMP (SECOND) SHAFT DISASSEMBLY .............................................................................................. 21-5-27 MASTER CLUTCH (FOURTH) SHAFT DISASSEMBLY .......................................................................... 21-5-33 OUTPUT (FIFTH) SHAFT DISASSEMBLY .............................................................................................. 21-5-41 COUNTER (THIRD) SHAFT DISASSEMBLY ........................................................................................... 21-5-48 CLEANING AND INSPECTION ................................................................................................................ 21-5-50 CLUTCH PACK CLEARANCE AND CLUTCH PACK TRAVEL TEST ..................................................... 21-5-52 1F, 1R, 2F AND 2R CLUTCH GEAR BEARING PRELOAD TEST .......................................................... 21-5-55 INPUT (FIRST) SHAFT ASSEMBLY ....................................................................................................... 21-5-58 PUMP (SECOND) SHAFT ASSEMBLY .................................................................................................... 21-5-72 MASTER CLUTCH (FOURTH) SHAFT ASSEMBLY ................................................................................ 21-5-82 OUTPUT (FIFTH) SHAFT ASSEMBLY .................................................................................................... 21-5-96 COUNTER (THIRD) SHAFT BEARING ASSEMBLY ............................................................................. 21-5-107 TRANSMISSION ASSEMBLY ................................................................................................................ 21-5-110 16 SPEED POWERSHIFT TRANSMISSION - HOW IT WORKS ..SECTION 21, CHAPTER 6 (Book 2 - 87525640) GENERAL DESCRIPTION OF OPERATION ........................................................................................... 21-6-3 Regulator Valve ......................................................................................................................................... 21-6-4 Lube Regulator Valve ................................................................................................................................ 21-6-5 Master Clutch Lube Valve ........................................................................................................................... 21-6-5 Range Selector Valve ............................................................................................................................... 21-6-6 MASTER CLUTCH CONTROL VALVE ..................................................................................................... 21-6-7 Transmission Power Flow ......................................................................................................................... 21-6-8 Default Settings ......................................................................................................................................... 21-6-8 Helical-cut Gears ....................................................................................................................................... 21-6-8 Shifting The Powershift Transmission ....................................................................................................... 21-6-9 REAR DRIVE LINE AND CARRIER BEARING..............................SECTION 21, CHAPTER 7 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-7-2 REAR DRIVE LINE AND CARRIER BEARING REMOVAL ..................................................................... 21-7-3 REAR DRIVE LINE AND CARRIER BEARING INSTALLATION ............................................................... 21-7-5 CHARGE PUMP REPAIR FOR 16-SPEED POWERSHIFT TRANSMISSION ...................................................SECTION 21, CHAPTER 8 (Book 2 - 87525640) SPECIFICATIONS ...................................................................................................................................... 21-8-3 SPECIAL TORQUE VALUES ..................................................................................................................... 21-8-3 PUMP DISASSEMBLY ............................................................................................................................... 21-8-4 PUMP ASSEMBLY ..................................................................................................................................... 21-8-7
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 6 24 SPEED MANUAL TRANSMISSION REMOVAL AND INSTALLATION .....................................................................SECTION 21, CHAPTER 9 (Book 2 - 87525640) SPECIAL TOOLS ........................................................................................................................................ 21-9-3 SPECIAL TORQUE VALUES ..................................................................................................................... 21-9-3 24 SPEED TRANSMISSION REMOVAL .................................................................................................... 21-9-4 24 SPEED TRANSMISSION INSTALLATION .......................................................................................... 21-9-13 MASTER CLUTCH ADJUSTMENT .......................................................................................................... 21-9-23 SHIFT LEVER LINKAGE ADJUSTMENT ................................................................................................. 21-9-24 ENGINE/TRANSMISSION DRIVE COUPLER REMOVE/INSTALL - TJ380/430 ..................................................SECTION 21, CHAPTER 10 (Book 2 - 87525640) SPECIAL TORQUE VALUES ................................................................................................................... 21-10-2 DRIVE COUPLER REMOVAL ................................................................................................................. 21-10-3 DRIVE COUPLER INSTALLATION .......................................................................................................... 21-10-6 24 SPEED MANUAL TRANS HOW IT WORKS/ PRESSURE TESTING/REPAIR...................................................SECTION 21, CHAPTER 11 (Book 2 - 87525640) SPECIFICATIONS .................................................................................................................................... 21-11-4 SPECIAL TORQUE VALUES ................................................................................................................... 21-11-5 SPECIAL TOOLS ..................................................................................................................................... 21-11-6 PRESSURE TESTING SPECIFICATIONS ............................................................................................... 21-11-8 GENERAL SETUP PROCEDURE ............................................................................................................ 21-11-9 TRANSMISSION PRESSURE TEST PORT LOCATIONS ..................................................................... 21-11-11 TESTING THE LUBRICATION PRESSURE .......................................................................................... 21-11-13 TRANSMISSION SERIAL NUMBER IDENTIFICATION ......................................................................... 21-11-14 TRANSMISSION LUBRICATION CIRCUIT ............................................................................................ 21-11-15 TRANSMISSION OIL FLOW CHART ..................................................................................................... 21-11-16 DESCRIPTION OF OPERATION .......................................................................................................... 21-11-20 TRANSMISSION POWER FLOW ........................................................................................................... 21-11-24 STARTING IN A FORWARD SPEED ..................................................................................................... 21-11-26 STARTING IN A REVERSE SPEED ...................................................................................................... 21-11-27 TROUBLESHOOTING GUIDE ............................................................................................................... 21-11-35 NEUTRAL SAFETY SWITCH ADJUSTMENT ..................................................................................... 21-11-40 TRANSMISSION SPEED SENSOR ADJUSTMENT .............................................................................. 21-11-40 TRANSMISSION DISASSEMBLY .......................................................................................................... 21-11-41 SHIFT LEVER SEAL REPLACEMENT ................................................................................................. 21-11-53 INPUT SHAFT DISASSEMBLY .............................................................................................................. 21-11-54 INPUT SHAFT ASSEMBLY .................................................................................................................... 21-11-59 PUMP SHAFT DISASSEMBLY ............................................................................................................. 21-11-72 PUMP SHAFT ASSEMBLY .................................................................................................................... 21-11-75 SPEED SHAFT DISASSEMBLY ........................................................................................................... 21-11-81 SPEED SHAFT ASSEMBLY ................................................................................................................... 21-11-84 CENTER SHAFT DISASSEMBLY .......................................................................................................... 21-11-88 CENTER SHAFT ASSEMBLY ................................................................................................................ 21-11-90 RANGE SHAFT DISASSEMBLY ............................................................................................................ 21-11-94 RANGE SHAFT ASSEMBLY ................................................................................................................ 21-11-967 TRANSMISSION ASSEMBLY ............................................................................................................. 21-11-100 HIGH-LOW CLUTCH CONTROL ASSEMBLY ................................................................................... 21-11-118 HIGH-LOW CONTROL VALVE DISASSEMBLY .................................................................................. 21-11-119 REGULATOR VALVE ASSEMBLY ....................................................................................................... 21-11-121 REGULATOR VALVE DISASSEMBLY AND ASSEMBLY .................................................................... 21-11-122 MASTER CLUTCH CONTROL VALVE ASSEMBLY ............................................................................ 21-11-123 MASTER CLUTCH CONTROL VALVE DISASSEMBLY AND ASSEMBLY ......................................... 21-11-124 LOCKOUT VALVE ASSEMBLY ............................................................................................................ 21-11-126 LOCKOUT VALVE DISASSEMBLY AND ASSEMBLY ......................................................................... 21-11-127 MASTER CLUTCH CABLE ADJUSTMENT ......................................................................................... 21-11-128
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 7 16-SPEED POWERSHIFT TRANSMISSION - PRESSURE TESTING AND TROUBLESHOOTING ................ SECTION 21, CHAPTER 12 (Book 2A - 87740916) RECOMMENDED TOOLS ....................................................................................................................... 21-12-3 SPECIAL TORQUE VALUES ................................................................................................................... 21-12-4 TRANSMISSION TROUBLESHOOTING ................................................................................................ 21-12-5 Important General Information ................................................................................................................ 21-12-5 Fault Code Retrieval ............................................................................................................................... 21-12-5 Fault Codes Recorded ............................................................................................................................ 21-12-6 No Fault Codes Recorded ....................................................................................................................... 21-12-7 Solenoid Swap Test ................................................................................................................................ 21-12-8 CLUTCH TEST PORT IDENTIFICATION ................................................................................................. 21-12-9 Transmission Clutch Pressure Test ...................................................................................................... 21-12-10 TEST PORT IDENTIFICATION .............................................................................................................. 21-12-15 PRESSURE TEST SPECIFICATIONS AND WORKSHEETS ................................................................ 21-12-16 LUBE TEST PORT IDENTIFICATION .................................................................................................... 21-12-19 LUBRICATION CIRCUIT PRESSURE TEST ....................................................................................... 21-12-20 MASTER CLUTCH LUBE TEST ............................................................................................................. 21-12-22 PTO CLUTCH PRESSURE TEST .......................................................................................................... 21-12-23 PTO AND TRANSMISSION PRESSURE TEST REASSEMBLY ........................................................... 21-12-25 16 SPEED POWERSHIFT TRANSMISSION, RANGE SELECTOR, PRESSURE REGULATOR AND MASTER CLUTCH VALVE REPAIR ......................................... SECTION 21, CHAPTER 13 (Book 2A - 87740916) SPECIAL TORQUE VALUES ................................................................................................................... 21-13-3 REGULATOR VALVE DISASSEMBLY ..................................................................................................... 21-13-4 CLEANING, INSPECTION AND SOLENOID VALVE TEST ................................................................... 21-13-12 REGULATOR VALVE ASSEMBLY ......................................................................................................... 21-13-15 RANGE SELECTOR VALVE DYNAMIC TEST ...................................................................................... 21-13-23 RANGE SELECTOR PWM VALVE TEST .............................................................................................. 21-13-26 RANGE SELECTOR VALVE DISASSEMBLY ........................................................................................ 21-13-29 RANGE SELECTOR VALVE ASSEMBLY .............................................................................................. 21-13-32 PTO SYSTEM HOW IT WORKS AND TROUBLESHOOTING ......SECTION 31, CHAPTER 1 (Book 3 - 87525644) POWER TAKE OFF, General Information .................................................................................................. 31-1-3 PTO LUBRICATION, General Information .................................................................................................. 31-1-4 PTO CONTROL PTO Control Switch ................................................................................................................................... 31-1-5 To Operate the PTO .................................................................................................................................. 31-1-5 To Stop the PTO ....................................................................................................................................... 31-1-5 PTO Electrical Circuit ................................................................................................................................ 31-1-6 PTO Switch in the OFF Position ............................................................................................................... 31-1-7 PTO Switch in the ON Position ................................................................................................................. 31-1-8 Diode Suppressed PTO Coil ..................................................................................................................... 31-1-9 Neutral Start Feature ................................................................................................................................. 31-1-9 PTO VALVE Operational Modes .................................................................................................................................. 31-1-10 PTO Control Valve Operation ................................................................................................................. 31-1-12 PTO Clutch Disengaged ......................................................................................................................... 31-1-13 PTO Modulated Engagement .................................................................................................................. 31-1-14 PTO Fully Engaged ................................................................................................................................. 31-1-15 PTO Clutch Drive .................................................................................................................................... 31-1-16 PTO Clutch .............................................................................................................................................. 31-1-17 PTO Brake .............................................................................................................................................. 31-1-18 PTO Drop Box and Clutch ....................................................................................................................... 31-1-19 Engine RPM Speed Circuit ..................................................................................................................... 31-1-19
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 8 PTO SYSTEM TROUBLESHOOTING PTO Will Not Engage .............................................................................................................................. 31-1-20 PTO Will Not Disengage ......................................................................................................................... 31-1-21 PTO CLUTCH REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 31, CHAPTER 2 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-2-2 PTO CLUTCH ASSEMBLY REMOVAL ..................................................................................................... 31-2-3 PTO CLUTCH ASSEMBLY INSTALLATION ............................................................................................. 31-2-9 PTO DRIVE UNIT (CLUTCH) REPAIR ..........................................SECTION 31, CHAPTER 3 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-3-3 SPECIFICATIONS ...................................................................................................................................... 31-3-3 PTO DRIVE UNIT DISASSEMBLY ............................................................................................................ 31-3-4 PTO DRIVE UNIT ASSEMBLY (EXPLODED VIEW) ................................................................................ 31-3-13 PTO CLUTCH AND BRAKE ASSEMBLY (EXPLODED VIEW) ................................................................ 31-3-14 PTO DRIVE UNIT ASSEMBLY ................................................................................................................ 31-3-15 PTO CLUTCH REMOVAL AND INSTALLATION - TJ280/330.......SECTION 31, CHAPTER 4 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-4-2 PTO CLUTCH REMOVAL .......................................................................................................................... 31-4-3 PTO CLUTCH INSTALLATION .................................................................................................................. 31-4-5 PTO TRANSFER CASE REMOVAL AND INSTALLATION ...........SECTION 31, CHAPTER 5 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-5-2 SPECIAL TOOLS ........................................................................................................................................ 31-5-2 TRANSFER CASE REMOVAL .................................................................................................................. 31-5-3 TRANSFER CASE INSTALLATION ........................................................................................................ 31-5-10 PTO DROPBOX REPAIR...............................................................SECTION 31, CHAPTER 6 (Book 3 - 87525644) SPECIFICATIONS ...................................................................................................................................... 31-6-2 SPECIAL TORQUE VALUES ..................................................................................................................... 31-6-2 PTO DROPBOX DISASSEMBLY .............................................................................................................. 31-6-3 EXPLODED VIEW PTO DROPBOX ASSEMBLY ...................................................................................... 31-6-9 PTO DROPBOX ASSEMBLY ................................................................................................................... 31-6-10 PTO DRIVELINE HANGER BEARING..............................................SECTION 31, CHAPTER (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-7-2 PTO DRIVELINE HANGER BEARING REMOVAL .................................................................................... 31-7-3 HANGER BEARING ASSEMBLY REPAIR (Exploded View) ..................................................................... 31-7-5 HANGER BEARING DISASSEMBLY ......................................................................................................... 31-7-6 HANGER BEARING ASSEMBLY ............................................................................................................... 31-7-7 PTO DRIVELINE HANGER BEARING INSTALLATION .......................................................................... 31-7-10 PTO CLUTCH VALVE....................................................................SECTION 31, CHAPTER 8 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-8-2 PTO VALVE REMOVAL ............................................................................................................................. 31-8-3 PTO VALVE DISASSEMBLY ...................................................................................................................... 31-8-4 CLEANING AND INSPECTION .................................................................................................................. 31-8-7 PTO VALVE SOLENOID TESTS ............................................................................................................... 31-8-8 PTO VALVE SECTIONAL VIEW ................................................................................................................ 31-8-9 PTO VALVE ASSEMBLY .......................................................................................................................... 31-8-10 PTO VALVE INSTALLATION ................................................................................................................... 31-8-13
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 9 POWER BRAKES SYSTEM - HOW IT WORKS AND TROUBLESHOOTING ..............................SECTION 33, CHAPTER 1 (Book 3 - 87525644) BRAKE SYSTEM ........................................................................................................................................ 33-1-3 General Information .................................................................................................................................. 33-1-3 General Description .................................................................................................................................. 33-1-4 Axle Pump ................................................................................................................................................. 33-1-4 Axle Cooling Filter ..................................................................................................................................... 33-1-5 Axle Lube Solenoid Valve ......................................................................................................................... 33-1-5 Pressure/Lube Control Valve .................................................................................................................... 33-1-6 Brake Lubrication and Jet Pump ............................................................................................................... 33-1-6 Pressure/Lube Control Valve .................................................................................................................... 33-1-7 Regulated Pressure Spool ...................................................................................................................... 33-1-8 Park Brake/Tow Valve ............................................................................................................................. 33-1-10 Park Brake Applied ................................................................................................................................ 33-1-11 Park Brake Released ............................................................................................................................ 33-1-11 Tow Valve .............................................................................................................................................. 33-1-11 BRAKE CIRCUIT COMPONENTS .......................................................................................................... 33-1-12 Brake Pedal ........................................................................................................................................... 33-1-12 Brake Control Valve .............................................................................................................................. 33-1-13 Brake Clutch Pack ................................................................................................................................. 33-1-13 Axle Brake Cylinders ............................................................................................................................. 33-1-13 HYDRAULIC BRAKE CONTROL ............................................................................................................ 33-1-14 General Description ............................................................................................................................... 33-1-14 Brake Valve ........................................................................................................................................... 33-1-14 Service Brake Circuit ............................................................................................................................. 33-1-15 Emergency Braking ............................................................................................................................... 33-1-18 BRAKE SYSTEM TROUBLESHOOTING................................................................................................... 33-1-19 SERVICE BRAKE VALVE..............................................................SECTION 33, CHAPTER 2 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 33-2-2 RECOMMENDED TOOLS .......................................................................................................................... 33-2-2 SERVICE BRAKE VALVE REMOVAL ....................................................................................................... 33-2-3 SERVICE BRAKE VALVE DISASSEMBLY ................................................................................................ 33-2-6 INSPECTION AND CLEANING .................................................................................................................. 33-2-8 BRAKE MAL-FUNCTION SWITCH TEST .................................................................................................. 33-2-8 SERVICE BRAKE VALVE EXPLODED VIEW ............................................................................................ 33-2-9 SERVICE BRAKE VALVE SECTIONAL VIEW ......................................................................................... 33-2-10 SERVICE BRAKE VALVE ASSEMBLY ................................................................................................... 33-2-11 SERVICE BRAKE VALVE INSTALLATION .............................................................................................. 33-2-13 2006 AND 2007 MODEL YEAR HYDRAULIC SCHEMATIC .....................................................POSTER 87522497 2008 MODEL YEAR HYDRAULIC SCHEMATIC .......................................................................POSTER 87722947 HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC ......SECTION 35, CHAPTER 1 (Book 4 - 87618159) Introduction ............................................................................................................................................... 35-1-3 Circuit Diagrams ........................................................................................................................................ 35-1-3 Symbol Systems ....................................................................................................................................... 35-1-3 Using Schematic Symbols ........................................................................................................................ 35-1-3 Reservoirs ............................................................................................................................................... 35-1-3 Lines, Tubes and Hoses .......................................................................................................................... 35-1-4 Crossing or Joining Lines ........................................................................................................................ 35-1-5 Pump Symbols ........................................................................................................................................ 35-1-5 Hydraulic Motor Symbols ........................................................................................................................ 35-1-6 Cylinder Symbols .................................................................................................................................... 35-1-6
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 10 Pressure Control Symbols ........................................................................................................................ 35-1-7 Normally Closed ...................................................................................................................................... 35-1-7 Normally Open ........................................................................................................................................ 35-1-7 Relief Valve ............................................................................................................................................. 35-1-7 Pressure Reducing Valve ........................................................................................................................ 35-1-7 Sequence Valve ...................................................................................................................................... 35-1-8 Directional Control Symbols ...................................................................................................................... 35-1-8 Simplified Symbols .................................................................................................................................. 35-1-8 One Way Valve ....................................................................................................................................... 35-1-8 By Pass Valve ......................................................................................................................................... 35-1-8 Composite Symbols .................................................................................................................................. 35-1-8 One Way Valves ...................................................................................................................................... 35-1-8 Two Position Valves ................................................................................................................................ 35-1-8 Three Position Valves ............................................................................................................................. 35-1-9 Actuating Controls ................................................................................................................................... 35-1-9 Flow Control Symbols ............................................................................................................................... 35-1-9 Restrictors ............................................................................................................................................... 35-1-9 Accessories ............................................................................................................................................. 35-1-10 SIMPLE SCHEMATIC ............................................................................................................................... 35-1-12 COMMON SYMBOLS ............................................................................................................................... 35-1-14 Lines and Line Functions ........................................................................................................................ 35-1-14 Mechanical Devices ................................................................................................................................ 35-1-14 Pumps and Motors .................................................................................................................................. 35-1-14 Reservoirs ............................................................................................................................................... 35-1-15 Cylinders ................................................................................................................................................. 35-1-15 Valves ..................................................................................................................................................... 35-1-15 Valve Actuators ....................................................................................................................................... 35-1-17 Accessories................................................................................................................................................. 35-1-17 HYDRAULIC SYSTEM HOW IT WORKS WITH TROUBLESHOOTING .........................................................SECTION 35, CHAPTER 2 (Book 4 - 87618159) GENERAL INTRODUCTION ...................................................................................................................... 35-2-3 SPECIFICATIONS ...................................................................................................................................... 35-2-5 MODEL NUMBER LOCATION ................................................................................................................... 35-2-7 STANDARD AND HIGH FLOW PFC PISTON PUMPS .............................................................................. 35-2-8 Principle of Control .................................................................................................................................... 35-2-8 Engine Start Up ......................................................................................................................................... 35-2-8 Operating Modes ....................................................................................................................................... 35-2-8 Low Pressure Standby .............................................................................................................................. 35-2-8 Pressure and Flow Delivery and Compensation Principle ........................................................................ 35-2-8 Increased Flow Demand ........................................................................................................................... 35-2-9 Decreased Flow Demand .......................................................................................................................... 35-2-9 High Pressure Standby ............................................................................................................................. 35-2-9 Return to Low Pressure Standby .............................................................................................................. 35-2-9 Destroke Valve .......................................................................................................................................... 35-2-9 Model 480 and 530 Tractor Hydraulic Fan Pump And Motor .................................................................. 35-2-10 PRESSURE/FLOW COMPENSATED PUMP ........................................................................................... 35-2-12 PFC CHARGE PRESSURE TEST ........................................................................................................... 35-2-14 LOW PRESSURE AND HIGH PRESSURE STANDBY TESTS ............................................................... 35-2-16 PFC PISTON PUMP FLOW TEST AT REMOTE COUPLERS ................................................................. 35-2-17 MEGAFLOW PUMP LOW PRESSURE AND HIGH PRESSURE STANDBY TESTS .............................. 35-2-18 MEGAFLOW PFC PISTON PUMP FLOW TEST AT REMOTE COUPLERS ........................................... 35-2-20 REGULATED PRESSURE TEST ............................................................................................................. 35-2-21 REGULATED PRESSURE ADJUSTMENT PROCEDURE ...................................................................... 35-2-22 REGULATED/LUBE PUMP TESTS .......................................................................................................... 35-2-23
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 11 480 and 530 HYDRAULIC FAN PUMP LOW PRESSURE STANDBY, HIGH PRESSURE AND FLOW TESTS .................................................................................................... 35-2-25 480 and 530 HYDRAULIC FAN MOTOR TEST ....................................................................................... 35-2-27 REGULATED PRESSURE / LUBE CONTROL SYSTEM ........................................................................ 35-2-28 REGULATOR VALVE ............................................................................................................................... 35-2-29 480 and 530 HYDRAULIC FAN CIRCUIT ................................................................................................ 35-2-30 480 and 530 HYDRAULIC FAN SYSTEM ................................................................................................ 35-2-31 STEERING PRIORITY VALVE ................................................................................................................. 35-2-32 HYDRAULIC FAN/MOTOR REMOVAL AND FAN MOTOR/PUMP REPAIR - TJ480/530....................................SECTION 35, CHAPTER 3 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 35-3-3 HYDRAULIC FAN AND FAN MOTOR REMOVAL ..................................................................................... 35-3-4 HYDRAULIC FAN AND FAN MOTOR INSTALLATION ........................................................................... 35-3-15 HYDRAULIC FAN PUMP REMOVAL ....................................................................................................... 35-3-28 HYDRAULIC FAN PUMP INSTALLATION ............................................................................................... 35-3-31 HYDRAULIC FAN MOTOR DISASSEMBLY ............................................................................................ 35-3-35 HYDRAULIC FAN MOTOR ASSEMBLY .................................................................................................. 35-3-39 COMPENSATOR CONTROL VALVE REMOVAL AND DISASSEMBLY ................................................. 35-3-42 COMPENSATOR CONTROL VALVE ASSEMBLY AND INSTALLATION ............................................... 35-3-43 HYDRAULIC FAN PUMP DISASSEMBLY ............................................................................................... 35-3-44 PUMP CLEANING AND INSPECTION ..................................................................................................... 35-3-51 PFC PISTON PUMP REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 35, CHAPTER 4 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 35-4-2 SPECIAL TOOLS ........................................................................................................................................ 35-4-2 PISTON PUMP REMOVAL ........................................................................................................................ 35-4-3 PISTON PUMP INSTALLATION ................................................................................................................ 35-4-8 START-UP PROCEDURE ........................................................................................................................ 35-4-13 GEAR PUMP REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 35, CHAPTER 5 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 35-5-2 SPECIAL TOOLS ........................................................................................................................................ 35-5-2 GEAR PUMP REMOVAL ........................................................................................................................... 35-5-3 GEAR PUMP INSTALLATION .................................................................................................................... 35-5-5 PFC AXIAL PISTON PUMP REPAIR.............................................SECTION 35, CHAPTER 6 (Book 4 - 87618159) SPECIFICATIONS ...................................................................................................................................... 35-6-3 SPECIAL TORQUE VALUES ..................................................................................................................... 35-6-4 PISTON PUMP DISASSEMBLY ................................................................................................................ 35-6-5 PRESSURE/FLOW COMPENSATOR DISASSEMBLY .......................................................................... 35-6-12 PISTON PUMP CLEANING AND INSPECTION .................................................................................... 35-6-16 PRESSURE/FLOW COMPENSATOR ASSEMBLY EXPLODED VIEW .................................................. 35-6-20 PRESSURE/FLOW COMPENSATOR ASSEMBLY ................................................................................ 35-6-21 PISTON PUMP ASSEMBLY EXPLODED VIEW ...................................................................................... 35-6-24 PISTON PUMP ASSEMBLY .................................................................................................................... 35-6-25
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 12 HITCH SYSTEM - HOW IT WORKS..............................................SECTION 35, CHAPTER 7 (Book 4 - 87618159) THREE POINT HITCH ................................................................................................................................ 35-7-3 ELECTRONIC HITCH CONTROL .............................................................................................................. 35-7-4 Operator Controls and Settings ................................................................................................................. 35-7-5 ELECTRONIC HITCH CONTROL SYSTEM FEATURES .......................................................................... 35-7-7 HITCH CONTROL VALVE ........................................................................................................................ 35-7-14 General ................................................................................................................................................... 35-7-14 Raise and Lower Solenoids .................................................................................................................... 35-7-14 Raise and Lower Pilot Spools ................................................................................................................. 35-7-14 Raise Spool ............................................................................................................................................. 35-7-14 Lower Poppet .......................................................................................................................................... 35-7-14 Load Check Ball ...................................................................................................................................... 35-7-14 Manual Raise or Lower Control Pins ....................................................................................................... 35-7-14 Overload Relief Valve ............................................................................................................................. 35-7-14 Neutral Function and Troubleshooting .................................................................................................... 35-7-16 Raise Function and Troubleshooting ...................................................................................................... 35-7-18 Raise Function and Troubleshooting ...................................................................................................... 35-7-19 Lower Function and Troubleshooting ...................................................................................................... 35-7-20 Lower Function and Troubleshooting ...................................................................................................... 35-7-21 THREE POINT HITCH VALVE.......................................................SECTION 35, CHAPTER 8 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 35-8-2 TPH VALVE REMOVAL ............................................................................................................................. 35-8-3 TPH VALVE DISASSEMBLY ..................................................................................................................... 35-8-5 CLEANING AND INSPECTION ................................................................................................................ 35-8-9 HITCH VALVE SOLENOID TEST ............................................................................................................. 35-8-11 THREE POINT HITCH VALVE ................................................................................................................. 35-8-13 TPH VALVE ASSEMBLY .......................................................................................................................... 35-8-14 TPH VALVE INSTALLATION .................................................................................................................... 35-8-18 REMOTE ELECTRONIC HYD SYSTEMS - HOW IT WORKS/TROUBLESHOOTING.......................................SECTION 35, CHAPTER 9 (Book 4 - 87618159) REMOTE HYDRAULIC SYSTEM INTRODUCTION .................................................................................. 35-9-3 REMOTE SYSTEM CONTROLS (ELECTRONIC) ..................................................................................... 35-9-5 Remote Function Control .......................................................................................................................... 35-9-6 Full Function Position ................................................................................................................................ 35-9-6 Neutral Lock Position ................................................................................................................................ 35-9-6 Float Lock-Out Position ............................................................................................................................. 35-9-7 Non-Detent Raise Position ........................................................................................................................ 35-9-7 Hydraulic Motor Position ........................................................................................................................... 35-9-7 Hydraulic Valve Timer Control .................................................................................................................. 35-9-9 Variable Flow Control ................................................................................................................................ 35-9-9 Remote Valve Load Check Valves .......................................................................................................... 35-9-10 REMOTE VALVE PROPORTIONAL CURRENT CONTROL (PCC) SOLENOID OPERATION .............. 35-9-11 REMOTE VALVE OPERATION (ELECTRONIC) ..................................................................................... 35-9-12 REMOTE VALVE PROBLEMS AND WHERE TO LOOK ......................................................................... 35-9-20 ELECTRONIC REMOTE VALVE SYSTEM TESTING ............................................................................. 35-9-21 FAULT CODE RETRIEVAL ...................................................................................................................... 35-9-21 REGULATED PRESSURE CHECK .......................................................................................................... 35-9-24 REMOTE VALVE HIGH PRESSURE TEST ............................................................................................. 35-9-24 REMOTE VALVE PROPORTIONAL SOLENOID CHECK ....................................................................... 35-9-26 LOW PRESSURE AND HIGH PRESSURE STANDBY TESTS ............................................................... 35-9-27 REMOTE VALVE FLOW TEST ................................................................................................................ 35-9-29 REMOTE VALVE SIGNAL CHECK AND HITCH SIGNAL CHECK TEST ................................................ 35-9-31 REMOTE VALVE COUPLER TEST ......................................................................................................... 35-9-32 LOAD CHECK INSPECTION .................................................................................................................... 35-9-33
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 13 HYDRAULIC GEAR (CHARGE) PUMP REPAIR .........................SECTION 35, CHAPTER 10 (Book 4 - 87618159) SPECIAL TORQUE VALUES ................................................................................................................... 35-10-2 PUMP DISASSEMBLY ............................................................................................................................. 35-10-3 CLEANING AND INSPECTION ................................................................................................................ 35-10-7 PUMP ASSEMBLY ................................................................................................................................... 35-10-8 HYDRAULIC FILTERS .................................................................SECTION 35, CHAPTER 11 (Book 4 - 87618159) SPECIFICATIONS .................................................................................................................................... 35-11-2 SERVICING THE HYDRAULIC AND TRANSMISSION OIL FILTERS ..................................................... 35-11-3 REMOTE AUXILIARY VALVE AND COUPLER, REMOVAL/INSTALLATION/REPAIR...........................................SECTION 35, CHAPTER 12 (Book 4 - 87618159) SPECIAL TORQUE VALUES ................................................................................................................... 35-12-3 REMOTE AUXILIARY VALVE MANIFOLD SEAL REPLACEMENT ........................................................ 35-12-4 REMOTE AUXILIARY VALVE SOLENOID TEST ................................................................................... 35-12-9 REMOTE AUXILIARY VALVE SOLENOID REMOVAL AND DISASSEMBLY ......................................... 35-12-9 REMOTE AUXILIARY VALVE SOLENOID ASSEMBLY AND INSTALLATION ..................................... 35-12-12 REMOTE AUXILIARY VALVE CONTROL SPOOL REMOVAL .............................................................. 35-12-15 REMOTE AUXILIARY VALVE CONTROL SPOOL INSTALLATION .................................................... 35-12-17 REMOTE AUXILIARY VALVE REMOVAL ............................................................................................. 35-12-19 REMOTE AUXILIARY VALVE SECTION DISASSEMBLY ..................................................................... 35-12-20 LOAD CHECK VALVE DISASSEMBLY ................................................................................................. 35-12-25 REMOTE AUXILIARY VALVE SECTION ASSEMBLY ........................................................................... 35-12-27 LOAD CHECK VALVE ASSEMBLY ....................................................................................................... 35-12-29 REMOTE AUXILIARY VALVE SECTION ASSEMBLY ........................................................................... 35-12-31 REMOTE AUXILIARY VALVE SECTION INSTALLATION ..................................................................... 35-12-36 HYDRAULIC GEAR PUMP AND PISTON PUMP REMOVE/INSTALL - TJ280/330 ..................................................SECTION 35, CHAPTER 13 (Book 4 - 87618159) SPECIAL TORQUE VALUES ................................................................................................................... 35-13-3 RECOMMENDED TOOLS ........................................................................................................................ 35-13-3 GEAR PUMP REMOVAL ......................................................................................................................... 35-13-4 GEAR PUMP INSTALLATION .................................................................................................................. 35-13-7 PFC PISTON PUMP REMOVAL .............................................................................................................. 35-13-9 PFC PISTON PUMP INSTALLATION ................................................................................................... 35-13-14 START-UP PROCEDURE ...................................................................................................................... 35-13-19 DRAWBAR REMOVAL AND INSTALLATION ...............................SECTION 37, CHAPTER 1 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 37-1-2 SPECIAL TOOLS ........................................................................................................................................ 37-1-2 DRAWBAR REMOVAL ............................................................................................................................... 37-1-3 DRAWBAR INSTALLATION ....................................................................................................................... 37-1-7 CENTER HINGE BEARINGS AND CONNECTING LINK - TJ380/430/480/530.........................................................................SECTION 39, CHAPTER 1 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 39-1-3 SPECIAL TOOL .......................................................................................................................................... 39-1-3 RECOMMENDED TOOLS .......................................................................................................................... 39-1-3 GENERAL INFORMATION ........................................................................................................................ 39-1-5 SEPARATING THE FRONT AND REAR FRAMES .................................................................................... 39-1-5 BOTTOM HINGE BEARING REPLACEMENT ....................................................................................... 39-1-11 CONNECTING LINK FRONT BUSHING REPLACEMENT ................................................................... 39-1-19 CONNECTING LINK REMOVAL .............................................................................................................. 39-1-21 CONNECTING LINK REAR BEARING REPLACEMENT ......................................................................... 39-1-22 CONNECTING LINK INSTALLATION ...................................................................................................... 39-1-23 CONNECTING THE FRONT AND REAR FRAMES .............................................................................. 39-1-25
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 14 CENTER HINGE BEARINGS AND CONNECTING LINK - TJ280/330.......................................................................................SECTION 39, CHAPTER 2 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 39-2-3 SPECIAL TOOL .......................................................................................................................................... 39-2-3 RECOMMENDED TOOLS .......................................................................................................................... 39-2-3 GENERAL INFORMATION ........................................................................................................................ 39-2-5 SEPARATING THE FRONT AND REAR FRAMES .................................................................................... 39-2-5 BOTTOM HINGE BEARING REPLACEMENT ....................................................................................... 39-2-11 CONNECTING LINK FRONT BUSHING REPLACEMENT ................................................................... 39-2-19 CONNECTING LINK REMOVAL .............................................................................................................. 39-2-21 CONNECTING LINK REAR BEARING REPLACEMENT ......................................................................... 39-2-22 CONNECTING LINK INSTALLATION ...................................................................................................... 39-2-23 CONNECTING THE FRONT AND REAR FRAMES .............................................................................. 39-2-25 CENTER HINGE BEARINGS AND CONNECTING LINK, T9030, 9040, 9050, AND 9060 S/N Z7F204001 AND AFTER.... SECTION 39, CHAPTER 3 (Book 4A - 87740917) SPECIAL TORQUE VALUES ..................................................................................................................... 39-3-3 SPECIAL TOOL .......................................................................................................................................... 39-3-3 RECOMMENDED TOOLS .......................................................................................................................... 39-3-3 GENERAL INFORMATION ........................................................................................................................ 39-3-5 SEPARATING THE FRONT AND REAR FRAMES .................................................................................... 39-3-5 BOTTOM HINGE BEARING REPLACEMENT ....................................................................................... 39-3-12 CONNECTING LINK FRONT BUSHING REPLACEMENT ................................................................... 39-3-20 CONNECTING LINK REMOVAL .............................................................................................................. 39-3-22 CONNECTING LINK REAR BEARING REPLACEMENT ......................................................................... 39-3-23 CONNECTING LINK INSTALLATION ...................................................................................................... 39-3-24 CONNECTING THE FRONT AND REAR FRAMES .............................................................................. 39-3-26 STEERING COLUMN REPAIR ......................................................SECTION 41, CHAPTER 1 (Book 5 - 87525646) TILT STEERING COLUMN DISASSEMBLY ............................................................................................. 41-1-3 TILT STEERING COLUMN ASSEMBLY .................................................................................................... 41-1-5 CENTER CONSOLE, STEERING COLUMN, PEDALS AND SWITCHES.............................................................SECTION 41, CHAPTER 2 (Book 5 - 87525646) SPECIAL TOOLS ........................................................................................................................................ 41-2-3 SPECIAL TORQUE VALUES ..................................................................................................................... 41-2-3 STEERING WHEEL REMOVAL ................................................................................................................ 41-2-4 TRANSMISSION SHIFT LEVER REMOVAL .............................................................................................. 41-2-4 CENTER CONSOLE COVER REMOVAL .................................................................................................. 41-2-7 CENTER CONSOLE COVER INSTALLATION .......................................................................................... 41-2-9 TRANSMISSION SHIFT INSTALLATION ................................................................................................. 41-2-11 STEERING WHEEL INSTALLATION ....................................................................................................... 41-2-14 STEERING COLUMN REMOVAL ........................................................................................................... 41-2-15 STEERING COLUMN INSTALLATION .................................................................................................... 41-2-16 TILT STEERING COLUMN RELEASE CABLE REMOVAL ................................................................... 41-2-17 TILT STEERING COLUMN RELEASE CABLE INSTALLATION .............................................................. 41-2-18 CLUTCH AND BRAKE PEDAL ASSEMBLY REMOVAL ........................................................................ 41-2-20 CLUTCH AND BRAKE PEDAL ASSEMBLY INSTALLATION .................................................................. 41-2-22 DECELERATION SWITCH REMOVAL ................................................................................................... 41-2-25 DECELERATION SWITCH INSTALLATION ............................................................................................ 41-2-26 CLUTCH POTENTIOMETER REMOVAL ............................................................................................... 41-2-27 CLUTCH POTENTIOMETER INSTALLATION ......................................................................................... 41-2-28 CLUTCH POTENTIOMETER CALIBRATION .......................................................................................... 41-2-29 CLUTCH POTENTIOMETER CALIBRATION .......................................................................................... 41-2-31 DIFFERENTIAL LOCK BRAKE SWITCH REMOVAL ............................................................................ 41-2-34 DIFFERENTIAL LOCK BRAKE SWITCH INSTALLATION ....................................................................... 41-2-34
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 15 HVAC PLENUM ACTUATOR MOTOR AND LOUVER REMOVAL ......................................................... 41-2-36 HVAC PLENUM ACTUATOR MOTOR AND LOUVER INSTALLATION .................................................. 41-2-39 TRANSMISSION SHIFT LEVER DISASSEMBLY .................................................................................. 41-2-42 TRANSMISSION SHIFT LEVER ASSEMBLY .......................................................................................... 41-2-49 STEERING HAND PUMP & PRIORITY/CONTROL VALVE REMOVE/INSTALL - TJ380/430/480/530 AND T9030/40/50/60 TRACTORS..........................................................SECTION 41, CHAPTER 3 (Book 5 - 87525646) SPECIAL TOOLS ........................................................................................................................................ 41-3-2 SPECIAL TORQUE VALUES ..................................................................................................................... 41-3-2 STEERING HAND PUMP REMOVAL ....................................................................................................... 41-3-3 STEERING TUBE LINES REMOVAL ......................................................................................................... 41-3-5 STEERING PRIORITY/CONTROL VALVE REMOVAL .............................................................................. 41-3-7 STEERING PRIORITY/CONTROL VALVE INSTALLATION ...................................................................... 41-3-8 STEERING TUBE LINES INSTALLATION ................................................................................................. 41-3-9 STEERING HAND PUMP INSTALLATION .............................................................................................. 41-3-11 STEERING HAND PUMP & PRIORITY/CONTROL VALVE REMOVE/INSTALL - TJ280/330 AND T9010/20 TRACTORS.......SECTION 41, CHAPTER 4 (Book 5 - 87525646) SPECIAL TOOLS ........................................................................................................................................ 41-4-2 SPECIAL TORQUE VALUES ..................................................................................................................... 41-4-2 STEERING HAND PUMP REMOVAL ....................................................................................................... 41-4-3 STEERING TUBE LINES REMOVAL ......................................................................................................... 41-4-5 STEERING PRIORITY/CONTROL VALVE REMOVAL .............................................................................. 41-4-7 STEERING PRIORITY/CONTROL VALVE INSTALLATION .................................................................... 41-4-10 STEERING TUBE LINES INSTALLATION ............................................................................................... 41-4-13 STEERING HAND PUMP INSTALLATION .............................................................................................. 41-4-15 STEERING SYSTEM HOW IT WORKS.........................................SECTION 41, CHAPTER 5 (Book 5 - 87525646) ELECTROHYDRAULIC STEERING SYSTEM (EHPS) .............................................................................. 41-5-3 PRIORITY / STEERING CONTROL VALVE (EHPS) ................................................................................. 41-5-4 EHPS STEERING SYSTEM ....................................................................................................................... 41-5-6 Engine Running Steering in Neutral Position ............................................................................................ 41-5-7 Engine Running, Turning Left ................................................................................................................... 41-5-9 EHPS Steering System ........................................................................................................................... 41-5-11 280 AND 330 MODELS STEERING LAYOUT ......................................................................................... 41-5-12 380, 430, 480 AND 530 MODELS STEERING LAYOUT ......................................................................... 41-5-13 FRONT AXLE REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 44, CHAPTER 1 (Book 5 - 87525646) SPECIAL TORQUE VALUES ..................................................................................................................... 44-1-3 SPECIAL TOOLS ........................................................................................................................................ 44-1-3 RECOMMENDED TOOLS .......................................................................................................................... 44-1-3 FRONT AXLE REMOVAL .......................................................................................................................... 44-1-4 FRONT AXLE INSTALLATION ................................................................................................................ 44-1-10 FRONT AXLE REMOVAL AND INSTALLATION - TJ280/330 .......SECTION 44, CHAPTER 2 (Book 5 - 87525646) SPECIAL TORQUE VALUES ....................................................................................................................... 44-2-3 SPECIAL TOOLS ........................................................................................................................................ 44-2-3 RECOMMENDED TOOLS .......................................................................................................................... 44-2-3 FRONT AXLE REMOVAL .......................................................................................................................... 44-2-4 FRONT AXLE INSTALLATION ................................................................................................................ 44-2-10
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 16 REAR AXLE REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 44, CHAPTER 3 (Book 5 - 87525646) SPECIAL TORQUE VALUES ..................................................................................................................... 44-3-3 SPECIAL TOOLS ........................................................................................................................................ 44-3-3 RECOMMENDED TOOLS .......................................................................................................................... 44-3-3 REAR AXLE REMOVAL ............................................................................................................................ 44-3-4 REAR AXLE INSTALLATION .................................................................................................................. 44-3-13 REAR AXLE REMOVAL AND INSTALLATION - TJ280/330 .........SECTION 44, CHAPTER 4 (Book 5 - 87525646) SPECIAL TORQUE VALUES ..................................................................................................................... 44-4-3 SPECIAL TOOLS ........................................................................................................................................ 44-4-3 RECOMMENDED TOOLS .......................................................................................................................... 44-4-3 REAR AXLE REMOVAL ............................................................................................................................ 44-4-4 REAR AXLE INSTALLATION .................................................................................................................. 44-4-12 FRONT AND REAR AXLE REPAIR - 300 SERIES AXLES...........SECTION 44, CHAPTER 5 (Book 5 - 87525646) AXLE SPECIFICATIONS ............................................................................................................................ 44-5-4 SPECIAL TORQUE VALUES ..................................................................................................................... 44-5-4 SPECIAL TOOLS ........................................................................................................................................ 44-5-5 RECOMMENDED TOOLS .......................................................................................................................... 44-5-6 GENERAL INFORMATION ....................................................................................................................... 44-5-12 AXLE FINAL DRIVE REMOVAL ............................................................................................................... 44-5-12 FINAL DRIVE DISASSEMBLY ................................................................................................................. 44-5-14 PLANETARY CARRIER DISASSEMBLY ................................................................................................. 44-5-18 PLANETARY CARRIER ASSEMBLY ....................................................................................................... 44-5-19 FINAL DRIVE HOUSING ASSEMBLY ...................................................................................................... 44-5-21 FRONT COVER REMOVAL ..................................................................................................................... 44-5-26 FRONT COVER DISASSEMBLY ............................................................................................................. 44-5-28 FRONT COVER ASSEMBLY ................................................................................................................... 44-5-31 RH SIDE BRAKE CARRIER REMOVAL .................................................................................................. 44-5-37 BRAKE CARRIER/BEARING SUPPORT DISASSEMBLY ....................................................................... 44-5-38 RH BRAKE CARRIER ASSEMBLY PROCEDURES ................................................................................ 44-5-42 DIFFERENTIAL REMOVAL ...................................................................................................................... 44-5-47 DIFFERENTIAL CASE DISASSEMBLY PROCEDURES ......................................................................... 44-5-48 DIFFERENTIAL CASE ASSEMBLY PROCEDURES ............................................................................... 44-5-51 LH DIFFERENTIAL BEARING CARRIER DISASSEMBLY ...................................................................... 44-5-57 LH DIFFERENTIAL BEARING CARRIER ASSEMBLY ............................................................................ 44-5-58 ADJUSTING BEVEL PINION GEAR DEPTH ........................................................................................... 44-5-59 SETTING DIFFERENTIAL CARRIER BEARING PRELOAD ................................................................... 44-5-62 SETTING RING/PINION GEAR BACKLASH ............................................................................................ 44-5-65 RH BEARING CARRIER/BRAKE SUPPORT INSTALLATION ................................................................ 44-5-69 FRONT COVER INSTALLATION ............................................................................................................. 44-5-70 LEAK TESTING THE SERVICE BRAKE .................................................................................................. 44-5-73 LEAK TESTING THE PARK BRAKE ........................................................................................................ 44-5-74 LEAK TESTING THE DIFFERENTIAL LOCK ........................................................................................... 44-5-75 FINAL DRIVE INSTALLATION ................................................................................................................. 44-5-77 FRONT AND REAR AXLE REPAIR - 500 SERIES AXLES..........SECTION 44, CHAPTER 6 (Book 5 - 87525646) AXLE IDENTIFICATION ............................................................................................................................. 44-6-4 AXLE SPECIFICATIONS ............................................................................................................................ 44-6-5 SPECIAL TORQUE VALUES ..................................................................................................................... 44-6-5 SPECIAL TOOLS ....................................................................................................................................... 44-6-6 RECOMMENDED TOOLS .......................................................................................................................... 44-6-8 GENERAL INFORMATION ....................................................................................................................... 44-6-13 AXLE FINAL DRIVE REMOVAL ............................................................................................................... 44-6-13 FINAL DRIVE DISASSEMBLY ................................................................................................................ 44-6-15
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 17 PLANETARY CARRIER DISASSEMBLY ................................................................................................ 44-6-19 PLANETARY CARRIER ASSEMBLY ....................................................................................................... 44-6-20 FINAL DRIVE HOUSING ASSEMBLY .................................................................................................... 44-6-22 PINION CARRIER REMOVAL .................................................................................................................. 44-6-28 PINION CARRIER DISASSEMBLY ......................................................................................................... 44-6-32 PINION CARRIER ASSEMBLY ................................................................................................................ 44-6-34 BRAKE CARRIER/BEARING SUPPORT REMOVAL ............................................................................ 44-6-39 BRAKE CARRIER/BEARING SUPPORT DISASSEMBLY ....................................................................... 44-6-40 RH BRAKE CARRIER ASSEMBLY PROCEDURES .............................................................................. 44-6-44 DIFFERENTIAL REMOVAL AND DISASSEMBLY ................................................................................. 44-6-49 DIFFERENTIAL CASE ASSEMBLY PROCEDURES ............................................................................. 44-6-53 LH DIFFERENTIAL BEARING SUPPORT DISASSEMBLY .................................................................. 44-6-59 LH DIFFERENTIAL BEARING SUPPORT ASSEMBLY ........................................................................... 44-6-60 ADJUSTING BEVEL PINION GEAR DEPTH ........................................................................................... 44-6-61 SETTING DIFFERENTIAL CARRIER BEARING PRELOAD ................................................................... 44-6-64 SETTING RING/PINION GEAR BACKLASH ............................................................................................ 44-6-67 CHECKING FOR CORRECT BEVEL PINION/GEAR TOOTH CONTACT ............................................ 44-6-68 BRAKE CARRIER/BEARING SUPPORT INSTALLATION ...................................................................... 44-6-70 PERFORMING THE BRAKE LEAK DOWN TEST ................................................................................... 44-6-73 DIFFERENTIAL LOCK LEAK TEST ......................................................................................................... 44-6-74 FINAL DRIVE INSTALLATION ................................................................................................................ 44-6-77 FRONT AND REAR AXLE REPAIR - 400 SERIES AXLES ...........SECTION 44, CHAPTER 7 (Book 5 - 87525646) AXLE IDENTIFICATION ............................................................................................................................. 44-7-4 AXLE SPECIFICATIONS ............................................................................................................................ 44-7-5 SPECIAL TORQUE VALUES ..................................................................................................................... 44-7-5 SPECIAL TOOLS ....................................................................................................................................... 44-7-6 RECOMMENDED TOOLS .......................................................................................................................... 44-7-7 GENERAL INFORMATION ....................................................................................................................... 44-7-13 AXLE FINAL DRIVE REMOVAL ............................................................................................................... 44-7-13 FINAL DRIVE DISASSEMBLY ................................................................................................................ 44-7-15 PLANETARY CARRIER DISASSEMBLY ................................................................................................. 44-7-19 PLANETARY CARRIER ASSEMBLY ....................................................................................................... 44-7-20 FINAL DRIVE HOUSING ASSEMBLY ...................................................................................................... 44-7-22 FRONT COVER REMOVAL ..................................................................................................................... 44-7-28 FRONT COVER DISASSEMBLY ............................................................................................................. 44-7-31 FRONT COVER ASSEMBLY ................................................................................................................... 44-7-33 RH SIDE BRAKE CARRIER REMOVAL .................................................................................................. 44-7-39 BRAKE CARRIER/BEARING SUPPORT DISASSEMBLY .................................................................... 44-7-40 RH BRAKE CARRIER ASSEMBLY PROCEDURES ................................................................................ 44-7-44 DIFFERENTIAL REMOVAL ..................................................................................................................... 44-7-49 DIFFERENTIAL CASE DISASSEMBLY PROCEDURES ......................................................................... 44-7-50 DIFFERENTIAL CASE ASSEMBLY PROCEDURES ............................................................................... 44-7-53 LH DIFFERENTIAL BEARING CARRIER DISASSEMBLY ................................................................... 44-7-59 LH DIFFERENTIAL BEARING CARRIER ASSEMBLY ............................................................................ 44-7-60 ADJUSTING BEVEL PINION GEAR DEPTH ........................................................................................... 44-7-61 SETTING DIFFERENTIAL CARRIER BEARING PRELOAD ................................................................... 44-7-64 SETTING RING/PINION GEAR BACKLASH ............................................................................................ 44-7-67 RH BEARING CARRIER/BRAKE SUPPORT INSTALLATION .............................................................. 44-7-71 FRONT COVER INSTALLATION ............................................................................................................. 44-7-72 LEAK TESTING THE SERVICE BRAKE .................................................................................................. 44-7-75 LEAK TESTING THE PARK BRAKE ........................................................................................................ 44-7-76 LEAK TESTING THE DIFFERENTIAL LOCK ........................................................................................... 44-7-77 FINAL DRIVE INSTALLATION ................................................................................................................. 44-7-79
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 18 AXLE COOLING AND LUBRICATION SYSTEM ...........................SECTION 44, CHAPTER 8 (Book 5 - 87525646) AXLE LUBRICATION CIRCUIT .................................................................................................................. 44-8-3 TESTING THE AXLE LUBRICATION CIRCUIT ......................................................................................... 44-8-7 Visual Inspection ....................................................................................................................................... 44-8-7 Axle Lubrication Pressure Test ................................................................................................................. 44-8-7 Air Flow Test ............................................................................................................................................. 44-8-7 Axle Pressure Test .................................................................................................................................... 44-8-7 300 SERIES AXLE LUBRICATION CIRCUIT ............................................................................................. 44-8-8 300 SERIES AXLE LUBRICATION CIRCUIT ............................................................................................. 44-8-9 400 SERIES AXLE LUBRICATION CIRCUIT ........................................................................................... 44-8-10 400 SERIES AXLE LUBRICATION CIRCUIT ........................................................................................... 44-8-11 500 SERIES AXLE LUBRICATION CIRCUIT ........................................................................................... 44-8-12 500 SERIES AXLE LUBRICATION CIRCUIT ........................................................................................... 44-8-13 AIR CONDITIONER SYSTEM SERVICE.......................................SECTION 50, CHAPTER 1 (Book 6 - 87525647) SPECIFICATIONS ...................................................................................................................................... 50-1-4 SPECIAL TORQUES .................................................................................................................................. 50-1-4 SPECIAL TOOLS ........................................................................................................................................ 50-1-4 SAFETY PROCEDURES ............................................................................................................................ 50-1-8 AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY .................................................................... 50-1-9 RECOVERING PURE 134A REFRIGERANT ........................................................................................... 50-1-11 RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691 ...................................................... 50-1-15 Preparing the Tank .................................................................................................................................. 50-1-15 Recovery Process ................................................................................................................................... 50-1-17 AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING ........................................................ 50-1-22 AIR CONDITIONING TEMPERATURE/PRESSURE CHART .................................................................. 50-1-27 LEAK DETECTION ................................................................................................................................... 50-1-28 Electronic Testing with OEM1437 ........................................................................................................... 50-1-29 Florescent Leak Detection ...................................................................................................................... 50-1-29 Fluorescent Dye Injection ...................................................................................................................... 50-1-30 Recovery Station Dye Injector Tool with a System in a Vacuum .......................................................... 50-1-30 Recovery Station Dye Injector Tool with a Charged System ................................................................. 50-1-31 Quick and Easy Dye Injector Tool with a Charged System ................................................................... 50-1-32 Compressor Oil Port .............................................................................................................................. 50-1-33 SP-20 PAG Oil Return Bottle ................................................................................................................ 50-1-34 Fluorescent Leak Testing ........................................................................................................................ 50-1-35 A/C SYSTEM FLUSHING PROCEDURE ................................................................................................. 50-1-36 Required Tools ........................................................................................................................................ 50-1-37 Precautions ............................................................................................................................................. 50-1-38 Component Flushing Procedure with Power Flush 17550 ...................................................................... 50-1-39 Complete Circuit Flushing Procedure with Power Flush 17550 .............................................................. 50-1-42 Back Flushing the Thermal Expansion Valve or Refrigerant Line ........................................................... 50-1-46 Post Flushing Procedures ....................................................................................................................... 50-1-48 Flushing Solvent Disposal ....................................................................................................................... 50-1-49 A/C SYSTEM COMPONENTS ................................................................................................................. 50-1-50 Cab HVAC Box Components - Automatic Temperature Control ............................................................. 50-1-50 TJ280/330 and T9010/20 Chassis Components ..................................................................................... 50-1-51 TJ380/430/480/530 and T9030/40/50/60 Chassis Components ............................................................. 50-1-53 A/C COMPRESSOR CLUTCH ................................................................................................................. 50-1-55 Clutch Removal ....................................................................................................................................... 50-1-55 Exploded View of Clutch ......................................................................................................................... 50-1-58 Compressor Clutch Replacement ........................................................................................................... 50-1-59
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 19 A/C COMPRESSOR ................................................................................................................................. 50-1-63 Oil Level Check or Adjustment ................................................................................................................ 50-1-63 Injection Method .................................................................................................................................... 50-1-63 Dipstick Method ..................................................................................................................................... 50-1-64 Compressor Removal - TJ280/330 and T9010/20 .................................................................................. 50-1-66 Compressor Installation - TJ280/330 and T9010/20 ............................................................................... 50-1-68 Compressor Removal - TJ380/430/480/530 and T9030/40/50/60 .......................................................... 50-1-70 Compressor Installation - TJ380/430/480/530 and T9030/40/50/60 ....................................................... 50-1-71 Compressor Belt Installation and Adjustment - TJ280/330 and T9010/20 .............................................. 50-1-72 THERMAL EXPANSION VALVE TESTING .............................................................................................. 50-1-73 THERMAL EXPANSION VALVE REPLACEMENT .................................................................................. 50-1-74 CONDENSER AND RECEIVER-DRIER ................................................................................................... 50-1-75 ACCESSING THE HVAC BOX ................................................................................................................. 50-1-76 EVAPORATOR TEMPERATURE SENSOR LOCATION ......................................................................... 50-1-77 BLOWER MOTOR REPLACEMENT ........................................................................................................ 50-1-78 HEATER CONTROL VALVE REPLACEMENT ........................................................................................ 50-1-78 EVAPORATOR/HEATER ASSEMBLY ..................................................................................................... 50-1-79 Evaporator/Heater Assembly Removal ................................................................................................... 50-1-79 Evaporator/Heater Assembly Installation ................................................................................................ 50-1-82 Post Replacement Procedures ............................................................................................................... 50-1-84 EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING ........................................................ 50-1-85 BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION .............................................................. 50-1-86 ATC CONTROLLER, BLOWER DRIVER & STANDARD A/C CONTROLLER REPLACEMENT ............ 50-1-87 ACCESSING AND REPLACING THE MODE DOOR MOTOR ................................................................ 50-1-88 CAB INTAKE AIR FILTER SERVICE ....................................................................................................... 50-1-91 CAB RECIRCULATION AIR FILTER SERVICE ....................................................................................... 50-1-92 CAB PRESSURIZATION TEST ................................................................................................................ 50-1-93 CAB PRESSURIZER MOTOR REPLACEMENT ...................................................................................... 50-1-95 VISCOUS FAN DRIVE .............................................................................................................................. 50-1-95 AIR CONDITIONING SYSTEM -TROUBLESHOOTING................SECTION 50, CHAPTER 2 (Book 5 - 87525646) SAFETY PROCEDURES ............................................................................................................................ 50-2-4 SPECIAL TOOLS ........................................................................................................................................ 50-2-5 A/C THERMAL OPERATION ...................................................................................................................... 50-2-6 A/C SYSTEM COMPONENTS ................................................................................................................... 50-2-8 Cab HVAC Box Components - Automatic Temperature Control ............................................................... 50-2-8 TJ280/330 and T9010/20 Chassis Components ..................................................................................... 50-2-10 TJ380/430/480/530 and T9030/40/50/60 Chassis Components ............................................................. 50-2-12 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION ............................................................. 50-2-14 ATC FAULT CODES ................................................................................................................................. 50-2-21 ATC Fault Code 111 ............................................................................................................................... 50-2-21 ATC Fault Code 112 ............................................................................................................................... 50-2-22 ATC Fault Code 115 ............................................................................................................................... 50-2-22 ATC Fault Code 116 ............................................................................................................................... 50-2-23 ATC Fault Code 120 ............................................................................................................................... 50-2-23 ATC Fault Code 121 ............................................................................................................................... 50-2-24 ATC Fault Code 122 ............................................................................................................................... 50-2-24 ATC Fault Code 125 ............................................................................................................................... 50-2-25 ATC Fault Code 126 ............................................................................................................................... 50-2-25 ATC Fault Code 127 ............................................................................................................................... 50-2-26 ATC Fault Code 128 ............................................................................................................................... 50-2-26 ATC Fault Code 129 ............................................................................................................................... 50-2-27 ATC Fault Code 130 ............................................................................................................................... 50-2-27 ATC Fault Code 131 ............................................................................................................................... 50-2-28 ATC Fault Code 132 ............................................................................................................................... 50-2-28 ATC Fault Code 133 ............................................................................................................................... 50-2-29 ATC Fault Code 134 ............................................................................................................................... 50-2-30
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 20 LOCATING SYSTEM PROBLEMS WITHOUT FAULT CODES ............................................................... 50-2-31 Controller-Based Resistance Tests ......................................................................................................... 50-2-31 ATC CONTROLLER TEST (CONNECTOR J8 TEST POINTS) ............................................................... 50-2-33 FIELD REPORTED SYMPTOMS/CAUSES ............................................................................................. 50-2-36 COMPRESSOR AND CLUTCH ................................................................................................................ 50-2-37 Operational Check .................................................................................................................................. 50-2-37 Electrical Test .......................................................................................................................................... 50-2-41 Compressor Clutch Control Circuit Test Procedure ................................................................................ 50-2-41 HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT ................................................. 50-2-44 Electrical Test .......................................................................................................................................... 50-2-46 High Pressure Switch and Circuit Test .................................................................................................... 50-2-46 Low Pressure Switch and Circuit Test .................................................................................................... 50-2-47 HEATER CONTROL VALVE .................................................................................................................... 50-2-48 Operational Check .................................................................................................................................. 50-2-48 Electrical Test .......................................................................................................................................... 50-2-49 Heater Control Valve Power, Signal and Ground Test ............................................................................ 50-2-49 BLOWER SPEED, TEMPERATURE CONTROL AND MODE DOOR POTS .......................................... 50-2-50 Electrical Test .......................................................................................................................................... 50-2-51 Common Control Potentiometer and Circuit Test Procedure .................................................................. 50-2-51 BLOWER AND BLOWER SPEED DRIVER ............................................................................................. 50-2-52 Blower Motor/Blower Driver Power, Signal and Ground Test ................................................................. 50-2-53 MODE DOOR CONTROL AND MOTOR .................................................................................................. 50-2-54 Electrical Test .......................................................................................................................................... 50-2-55 Mode Door Motor and Circuit Test .......................................................................................................... 50-2-55 CAB AND EVAPORATOR TEMPERATURE SENSORS ......................................................................... 50-2-56 Electrical Test .......................................................................................................................................... 50-2-57 Cab Temperature Sensor and Circuit Test ............................................................................................. 50-2-59 Evaporator Temperature Sensor and Circuit Test .................................................................................. 50-2-60 CONTROLLER POWER AND GROUND, ATC SWITCH ......................................................................... 50-2-62 Controller Power Supply and Ground Test ............................................................................................. 50-2-62 ATC Switch and Circuit Test ................................................................................................................... 50-2-63 Defog/Defrost Switch and Circuit Test .................................................................................................... 50-2-63 CAB PRESSURIZER BLOWER ............................................................................................................... 50-2-64 Cab Pressurizer Blower & Relay Power Supply and Ground Test .......................................................... 50-2-64 ACCESSING THE HVAC BOX ................................................................................................................. 50-2-65 2006 MODEL YEAR POWERSHIFT NAO ELECTRICAL SCHEMATIC ...................................POSTER 87517739 2007 MODEL YEAR POWERSHIFT NAO ELECTRICAL SCHEMATIC ...................................POSTER 87710064 2008 MODEL YEAR POWERSHIFT NAO ELECTRICAL SCHEMATIC ...................................POSTER 87708840
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 21 AIR CONDITIONING SYSTEM -TROUBLESHOOTING, MODELS T9020, 9030, 9040, 9050 AND 9060 AFTER SERIAL NUMBER Z7F204001 ...................................... SECTION 50, CHAPTER 3 (Book 6A - 87740918) SAFETY PROCEDURES ............................................................................................................................ 50-3-4 SPECIAL TOOLS ........................................................................................................................................ 50-3-5 A/C THERMAL OPERATION ...................................................................................................................... 50-3-6 A/C SYSTEM COMPONENTS ................................................................................................................... 50-3-8 Cab HVAC Box Components - Automatic Temperature Control ............................................................... 50-3-8 T9020 Chassis Components ................................................................................................................... 50-3-10 T9030, 9040 and 9050 Chassis Components ......................................................................................... 50-3-12 T9060 Chassis Components ................................................................................................................... 50-3-13 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION ............................................................. 50-3-15 ATC FAULT CODES ................................................................................................................................. 50-3-22 ATC Fault Code 111 ............................................................................................................................... 50-3-22 ATC Fault Code 112 ............................................................................................................................... 50-3-23 ATC Fault Code 115 ............................................................................................................................... 50-3-23 ATC Fault Code 116 ............................................................................................................................... 50-3-24 ATC Fault Code 120 ............................................................................................................................... 50-3-24 ATC Fault Code 121 ............................................................................................................................... 50-3-25 ATC Fault Code 122 ............................................................................................................................... 50-3-25 ATC Fault Code 125 ............................................................................................................................... 50-3-26 ATC Fault Code 126 ............................................................................................................................... 50-3-26 ATC Fault Code 127 ............................................................................................................................... 50-3-27 ATC Fault Code 128 ............................................................................................................................... 50-3-27 ATC Fault Code 129 ............................................................................................................................... 50-3-28 ATC Fault Code 130 ............................................................................................................................... 50-3-28 ATC Fault Code 131 ............................................................................................................................... 50-3-29 ATC Fault Code 132 ............................................................................................................................... 50-3-29 ATC Fault Code 133 ............................................................................................................................... 50-3-30 ATC Fault Code 134 ............................................................................................................................... 50-3-31 LOCATING SYSTEM PROBLEMS WITHOUT FAULT CODES ............................................................... 50-3-32 Controller-Based Resistance Tests ......................................................................................................... 50-3-32 ATC CONTROLLER TEST (CONNECTOR J8 TEST POINTS) ............................................................... 50-3-34 FIELD REPORTED SYMPTOMS/CAUSES ............................................................................................. 50-3-37 COMPRESSOR AND CLUTCH ................................................................................................................ 50-3-38 Operational Check .................................................................................................................................. 50-3-38 Electrical Test .......................................................................................................................................... 50-3-43 Compressor Clutch Control Circuit Test Procedure ................................................................................ 50-3-43 HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT ................................................. 50-3-46 Electrical Test .......................................................................................................................................... 50-3-48 High Pressure Switch and Circuit Test .................................................................................................... 50-3-48 Low Pressure Switch and Circuit Test .................................................................................................... 50-3-49 HEATER CONTROL VALVE .................................................................................................................... 50-3-50 Operational Check .................................................................................................................................. 50-3-50 Electrical Test .......................................................................................................................................... 50-3-51 Heater Control Valve Power, Signal and Ground Test ............................................................................ 50-3-51 BLOWER SPEED, TEMPERATURE CONTROL AND MODE DOOR POTS ......................................... 50-3-52 Electrical Test .......................................................................................................................................... 50-3-53 Common Control Potentiometer and Circuit Test Procedure .................................................................. 50-3-53 BLOWER AND BLOWER SPEED DRIVER ............................................................................................. 50-3-54 Blower Motor/Blower Driver Power, Signal and Ground Test ................................................................. 50-3-55 MODE DOOR CONTROL AND MOTOR .................................................................................................. 50-3-56 Electrical Test .......................................................................................................................................... 50-3-57 Mode Door Motor and Circuit Test .......................................................................................................... 50-3-57 CAB AND EVAPORATOR TEMPERATURE SENSORS ......................................................................... 50-3-58 Electrical Test .......................................................................................................................................... 50-3-59 Cab Temperature Sensor and Circuit Test ............................................................................................. 50-3-61
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 22 Evaporator Temperature Sensor and Circuit Test .................................................................................. 50-3-62 CONTROLLER POWER AND GROUND, ATC SWITCH ......................................................................... 50-3-64 Controller Power Supply and Ground Test ............................................................................................. 50-3-64 ATC Switch and Circuit Test ................................................................................................................... 50-3-65 Defog/Defrost Switch and Circuit Test .................................................................................................... 50-3-65 CAB PRESSURIZER BLOWER ............................................................................................................... 50-3-66 Cab Pressurizer Blower & Relay Power Supply and Ground Test .......................................................... 50-3-66 ACCESSING THE HVAC BOX ................................................................................................................. 50-3-67 ELECTRICAL SYSTEM - HOW IT WORKS AND TROUBLESHOOTING...........................................................SECTION 55, CHAPTER 1 (Book 7 - 87525648) SPECIAL TOOLS ........................................................................................................................................ 55-1-3 FUSE AND RELAY IDENTIFICATIONDELUXE CAB POWERSHIFT TRANSMISSION ........................... 55-1-4 FUSE AND RELAY IDENTIFICATIONDELUXE CAB 24 SPEED TRANSMISSION .................................. 55-1-6 INSTRUMENTATION AND CONTROLS .................................................................................................... 55-1-8 AUXILIARY AUTO MODE SWITCH (IF EQUIPPED) ............................................................................... 55-1-11 CONNECTOR AND COMPONENT LOCATION ...................................................................................... 55-1-13 ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS ............................................................... 55-1-89 AUDIO SYSTEM CIRCUIT OPERATION ................................................................................................. 55-1-90 CHARGING SYSTEM ............................................................................................................................... 55-1-95 POWER MIRROR SYSTEM ..................................................................................................................... 55-1-99 POWER SEAT SYSTEM ........................................................................................................................ 55-1-107 STARTING SYSTEM .............................................................................................................................. 55-1-112 WIPER / WASHER SYSTEM .................................................................................................................. 55-1-121 ELECTRONIC CONTROLLER CONFIG/CALIBRATION/ FAULT CODE RETRIVAL ..............................................................SECTION 55, CHAPTER 2 (Book 7 - 87525648) INSTRUMENTATION PROGRAMMING .................................................................................................... 55-2-3 Operation Setup ........................................................................................................................................ 55-2-3 Unit of Measure ......................................................................................................................................... 55-2-4 Tire Radius ................................................................................................................................................ 55-2-4 Radar Calibration ...................................................................................................................................... 55-2-7 Controller Configuration .......................................................................................................................... 55-2-10 ARMREST CONTROLLER CALIBRATION .............................................................................................. 55-2-15 Hitch Menu .............................................................................................................................................. 55-2-16 Throttle Menu .......................................................................................................................................... 55-2-18 Remote Valve Menu ................................................................................................................................ 55-2-18 TRANSMISSION CONTROLLER CALIBRATION .................................................................................... 55-2-23 Trans View Mode .................................................................................................................................... 55-2-25 Trans Setup Mode ................................................................................................................................... 55-2-33 Clutch Calibration Procedure .................................................................................................................. 55-2-35 Calibration Error Messages ..................................................................................................................... 55-2-40 Gear Default Mode .................................................................................................................................. 55-2-41 HITCH CONTROLLER CALIBRATION .................................................................................................... 55-2-43 Hitch Setting Menu .................................................................................................................................. 55-2-49 Hitch View Menu ..................................................................................................................................... 55-2-51 REMOTE HYDRAULICS CONTROLLER CALIBRATION ........................................................................ 55-2-52 Aux Setup Menu ...................................................................................................................................... 55-2-57 Aux Calibration Menu .............................................................................................................................. 55-2-58 Aux 67 Mode Lever Menu ....................................................................................................................... 55-2-72 FAULT CODE RETRIEVAL ...................................................................................................................... 55-2-74
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 23 ELECTRONIC CONTROLLER CONFIGURATION, CALIBRATION AND FAULT CODE RETRIEVAL FOR T9020, 9030, 9040, 9050, AND 9060 SERIES TRACTORS, S/N Z7F204001 and After....SECTION 55, CHAPTER 2A (Book 7A - 87740919) INSTRUMENTATION PROGRAMMING .................................................................................................. 55-2A-3 Operation Setup ...................................................................................................................................... 55-2A-3 Unit of Measure ....................................................................................................................................... 55-2A-4 Tire Radius .............................................................................................................................................. 55-2A-4 Radar Calibration .................................................................................................................................... 55-2A-7 Controller Configuration ........................................................................................................................ 55-2A-10 ARMREST CONTROLLER CALIBRATION ............................................................................................ 55-2A-15 Hitch Menu ............................................................................................................................................ 55-2A-16 Throttle Menu ........................................................................................................................................ 55-2A-19 Remote Valve Menu .............................................................................................................................. 55-2A-19 Exit Calibration ...................................................................................................................................... 55-2A-25 TRANSMISSION CONTROLLER CALIBRATION .................................................................................. 55-2A-26 Trans View Mode .................................................................................................................................. 55-2A-28 Trans Setup Mode ................................................................................................................................. 55-2A-36 Clutch Calibration Procedure ................................................................................................................ 55-2A-39 Calibration Error Messages ................................................................................................................... 55-2A-44 Gear Default Mode ................................................................................................................................ 55-2A-45 HITCH CONTROLLER CALIBRATION .................................................................................................. 55-2A-47 Hitch Setting Menu ................................................................................................................................ 55-2A-53 Hitch View Menu ................................................................................................................................... 55-2A-55 REMOTE HYDRAULICS CONTROLLER CALIBRATION ...................................................................... 55-2A-56 Aux Setup Menu .................................................................................................................................... 55-2A-61 Aux Calibration Menu ............................................................................................................................ 55-2A-62 Aux 67 Mode Lever Menu ..................................................................................................................... 55-2A-76 FAULT CODE RETRIEVAL .................................................................................................................... 55-2A-78 HITCH CONTROLLER FAULT CODES.........................................SECTION 55, CHAPTER 3 (Book 7 - 87525648) FAULT CODE HITCH 1020 ........................................................................................................................ 55-3-5 FAULT CODE HITCH 1030 ........................................................................................................................ 55-3-6 FAULT CODE HITCH 3010 ........................................................................................................................ 55-3-7 FAULT CODE HITCH 3020 ........................................................................................................................ 55-3-9 FAULT CODE HITCH 3030 ...................................................................................................................... 55-3-10 FAULT CODE HITCH 4019 ...................................................................................................................... 55-3-11 FAULT CODE HITCH 4029 ...................................................................................................................... 55-3-12 FAULT CODE HITCH 4039 ...................................................................................................................... 55-3-13 FAULT CODE HITCH 4049 ...................................................................................................................... 55-3-14 FAULT CODE HITCH 6014 ...................................................................................................................... 55-3-15 FAULT CODE HITCH 6015 ...................................................................................................................... 55-3-16 FAULT CODE HITCH 6024 ...................................................................................................................... 55-3-17 FAULT CODE HITCH 6025 ...................................................................................................................... 55-3-18 FAULT CODE HITCH 8001 ...................................................................................................................... 55-3-19 FAULT CODE HITCH 8002 ...................................................................................................................... 55-3-20 FAULT CODE HITCH 9301 ...................................................................................................................... 55-3-21 FAULT CODE HITCH 9302 ...................................................................................................................... 55-3-22 FAULT CODE HITCH 9303 ...................................................................................................................... 55-3-23 FAULT CODE HITCH 9304 ...................................................................................................................... 55-3-24 FAULT CODE HITCH 9306 ...................................................................................................................... 55-3-25 FAULT CODE HITCH 9307 ...................................................................................................................... 55-3-26 FAULT CODE HITCH 9308 ...................................................................................................................... 55-3-27 FAULT CODE HITCH 9309 ...................................................................................................................... 55-3-28 FAULT CODE HITCH 9310 ...................................................................................................................... 55-3-29 FAULT CODE HITCH 9311 ...................................................................................................................... 55-3-30 FAULT CODE HITCH 9312 ...................................................................................................................... 55-3-31 FAULT CODE HITCH 9313 ...................................................................................................................... 55-3-32
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 24 FAULT CODE HITCH 9314 ...................................................................................................................... 55-3-33 FAULT CODE HITCH 9315 ...................................................................................................................... 55-3-34 FAULT CODE HITCH 9316 ...................................................................................................................... 55-3-35 FAULT CODE HITCH 9317 ...................................................................................................................... 55-3-36 FAULT CODE HITCH 9318 ...................................................................................................................... 55-3-37 FAULT CODE HITCH 9319 ...................................................................................................................... 55-3-38 FAULT CODE HITCH 9320 ...................................................................................................................... 55-3-39 FAULT CODE HITCH 9321 ...................................................................................................................... 55-3-40 FAULT CODE HITCH 10030 .................................................................................................................... 55-3-41 FAULT CODE HITCH 10060 .................................................................................................................... 55-3-42 FAULT CODE HITCH 10061 .................................................................................................................... 55-3-43 FAULT CODE HITCH 10071 .................................................................................................................... 55-3-44 FAULT CODE HITCH 10072 .................................................................................................................... 55-3-45 FAULT CODE HITCH 10090 .................................................................................................................... 55-3-46 FAULT CODE HITCH 11010 .................................................................................................................... 55-3-47 FAULT CODE HITCH 11020 .................................................................................................................... 55-3-48 FAULT CODE HITCH 11030 .................................................................................................................... 55-3-49 FAULT CODE HITCH 11050 .................................................................................................................... 55-3-50 FAULT CODE HITCH 11069 .................................................................................................................... 55-3-51 FAULT CODE HITCH 11070 .................................................................................................................... 55-3-52 FAULT CODE HITCH 12011 .................................................................................................................... 55-3-53 FAULT CODE HITCH 12031 .................................................................................................................... 55-3-56 FAULT CODE HITCH 12041 .................................................................................................................... 55-3-58 FAULT CODE HITCH 52230 .................................................................................................................... 55-3-61 FAULT CODE HITCH 52260 .................................................................................................................... 55-3-62 FAULT CODE HITCH 65535 ..................................................................................................................... 55-3-63 TRANSMISSION CONTROLLER FAULT CODES ........................SECTION 55, CHAPTER 4 (Book 7 - 87525648) (TJ 280, 330, 380, 430, 480, and 530 Series and T9010, 20, 30, 40, 50, and 9060 Series Before S/N Z7F204001) FAULT CODE TRANS 11 ........................................................................................................................... 55-4-4 FAULT CODE TRANS 12 ........................................................................................................................... 55-4-5 FAULT CODE TRANS 24 ........................................................................................................................... 55-4-6 FAULT CODE TRANS 37 ........................................................................................................................... 55-4-7 FAULT CODE TRANS 38 ........................................................................................................................... 55-4-8 FAULT CODE TRANS 47 ........................................................................................................................... 55-4-9 FAULT CODE TRANS 48 ......................................................................................................................... 55-4-11 FAULT CODE TRANS 50 ......................................................................................................................... 55-4-12 FAULT CODE TRANS 51 ......................................................................................................................... 55-4-13 FAULT CODE TRANS 52 ......................................................................................................................... 55-4-14 FAULT CODE TRANS 53 ......................................................................................................................... 55-4-15 FAULT CODE TRANS 54 ......................................................................................................................... 55-4-17 FAULT CODE TRANS 59 ......................................................................................................................... 55-4-19 FAULT CODE TRANS 60 ......................................................................................................................... 55-4-20 FAULT CODE TRANS 66 ......................................................................................................................... 55-4-22 FAULT CODE TRANS 67 ......................................................................................................................... 55-4-23 FAULT CODE TRANS 68 ......................................................................................................................... 55-4-24 FAULT CODE TRANS 69 ......................................................................................................................... 55-4-25 FAULT CODE TRANS 70 ......................................................................................................................... 55-4-26 FAULT CODE TRANS 77 ......................................................................................................................... 55-4-27 FAULT CODE TRANS 80 ......................................................................................................................... 55-4-28 FAULT CODE TRANS 81 ......................................................................................................................... 55-4-30 FAULT CODE TRANS 83 ......................................................................................................................... 55-4-32 FAULT CODE TRANS 103 ....................................................................................................................... 55-4-33 FAULT CODE TRANS 104 ....................................................................................................................... 55-4-34 FAULT CODE TRANS 105 ....................................................................................................................... 55-4-35 FAULT CODE TRANS 106 ....................................................................................................................... 55-4-36 FAULT CODE TRANS 107 ....................................................................................................................... 55-4-37
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 25 FAULT CODE TRANS 108 ....................................................................................................................... 55-4-38 FAULT CODE TRANS 109 ....................................................................................................................... 55-4-39 FAULT CODE TRANS 110 ....................................................................................................................... 55-4-40 FAULT CODE TRANS 112 ....................................................................................................................... 55-4-41 FAULT CODE TRANS 113 ....................................................................................................................... 55-4-42 FAULT CODE TRANS 114 ....................................................................................................................... 55-4-43 FAULT CODE TRANS 115 ....................................................................................................................... 55-4-44 FAULT CODE TRANS 116 ....................................................................................................................... 55-4-45 FAULT CODE TRANS 117 ....................................................................................................................... 55-4-46 FAULT CODE TRANS 118 ....................................................................................................................... 55-4-47 FAULT CODE TRANS 119 ....................................................................................................................... 55-4-48 FAULT CODE TRANS 120 ....................................................................................................................... 55-4-49 FAULT CODE TRANS 122 ....................................................................................................................... 55-4-50 FAULT CODE TRANS 123 ....................................................................................................................... 55-4-51 FAULT CODE TRANS 125 ....................................................................................................................... 55-4-52 FAULT CODE TRANS 126 ....................................................................................................................... 55-4-53 FAULT CODE TRANS 127 ....................................................................................................................... 55-4-54 FAULT CODE TRANS 128 ....................................................................................................................... 55-4-55 FAULT CODE TRANS 129 ....................................................................................................................... 55-4-56 FAULT CODE TRANS 130 ....................................................................................................................... 55-4-57 FAULT CODE TRANS 131 ....................................................................................................................... 55-4-58 FAULT CODE TRANS 132 ....................................................................................................................... 55-4-59 FAULT CODE TRANS 133 ....................................................................................................................... 55-4-60 FAULT CODE TRANS 135 ....................................................................................................................... 55-4-61 FAULT CODE TRANS 136 ....................................................................................................................... 55-4-63 FAULT CODE TRANS 146 ....................................................................................................................... 55-4-65 FAULT CODE TRANS 147 ....................................................................................................................... 55-4-66 FAULT CODE TRANS 148 ....................................................................................................................... 55-4-68 ARMREST CONTROLLER FAULT CODES ..................................SECTION 55, CHAPTER 5 (Book 7 - 87525648) (TJ 280, 330, 380, 430, 480, and 530 Series and T9010, 20, 30, 40, 50, and 9060 Series Before S/N Z7F204001) FAULT CODE ARM 19 ............................................................................................................................... 55-5-4 FAULT CODE ARM 29 ............................................................................................................................... 55-5-5 FAULT CODE ARM 39 ............................................................................................................................... 55-5-6 FAULT CODE ARM 49 ............................................................................................................................... 55-5-7 FAULT CODE ARM 59 ............................................................................................................................... 55-5-8 FAULT CODE ARM 69 ............................................................................................................................... 55-5-9 FAULT CODE ARM 79 ............................................................................................................................. 55-5-10 FAULT CODE ARM 89 ............................................................................................................................. 55-5-11 FAULT CODE ARM 99 ............................................................................................................................. 55-5-12 FAULT CODE ARM 109 ........................................................................................................................... 55-5-13 FAULT CODE ARM 119 ........................................................................................................................... 55-5-14 FAULT CODE ARM 129 ........................................................................................................................... 55-5-15 FAULT CODE ARM 139 ........................................................................................................................... 55-5-16 FAULT CODE ARM 149 ........................................................................................................................... 55-5-17 FAULT CODE ARM 159 ........................................................................................................................... 55-5-18 FAULT CODE ARM 169 ........................................................................................................................... 55-5-19 FAULT CODE ARM 1019 ......................................................................................................................... 55-5-20 FAULT CODE ARM 1029 ......................................................................................................................... 55-5-21 FAULT CODE ARM 1039 ......................................................................................................................... 55-5-22 FAULT CODE ARM 1049 ......................................................................................................................... 55-5-23 FAULT CODE ARM 1059 ......................................................................................................................... 55-5-24 FAULT CODE ARM 1069 ......................................................................................................................... 55-5-25 FAULT CODE ARM 1079 ......................................................................................................................... 55-5-26 FAULT CODE ARM 1109 ......................................................................................................................... 55-5-27 FAULT CODE ARM 1119 ......................................................................................................................... 55-5-28 FAULT CODE ARM 1129 ......................................................................................................................... 55-5-29
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 26 FAULT CODE ARM 1139 ......................................................................................................................... 55-5-30 FAULT CODE ARM 8011 ......................................................................................................................... 55-5-31 FAULT CODE ARM 9011 ......................................................................................................................... 55-5-32 FAULT CODE ARM 9012 ......................................................................................................................... 55-5-33 FAULT CODE ARM 9013 ......................................................................................................................... 55-5-34 FAULT CODE ARM 9014 ......................................................................................................................... 55-5-35 FAULT CODE ARM 9015 ......................................................................................................................... 55-5-36 FAULT CODE ARM 9021 ......................................................................................................................... 55-5-37 FAULT CODE ARM 9031 ......................................................................................................................... 55-5-38 FAULT CODE ARM 10091 ....................................................................................................................... 55-5-39 FAULT CODE ARM 12013 ....................................................................................................................... 55-5-40 FAULT CODE ARM 12081 ....................................................................................................................... 55-5-42 FAULT CODE ARM 65535 ....................................................................................................................... 55-5-44 REMOTE HYDRAULICS CONTROLLER FAULT CODES ............SECTION 55, CHAPTER 6 (Book 8 - 87525649) FAULT CODE AUX - 1030 .......................................................................................................................... 55-6-5 FAULT CODE AUX 1040 ............................................................................................................................ 55-6-6 FAULT CODE AUX 1050 ............................................................................................................................ 55-6-7 FAULT CODE AUX 1060 ............................................................................................................................ 55-6-8 FAULT CODE AUX 1090 ............................................................................................................................ 55-6-9 FAULT CODE AUX 1100 .......................................................................................................................... 55-6-10 FAULT CODE AUX 8011 .......................................................................................................................... 55-6-11 FAULT CODE AUX 8012 .......................................................................................................................... 55-6-12 FAULT CODE AUX 9009 .......................................................................................................................... 55-6-13 FAULT CODE AUX 9019 .......................................................................................................................... 55-6-14 FAULT CODE AUX 9029 .......................................................................................................................... 55-6-15 FAULT CODE AUX 11010 ........................................................................................................................ 55-6-16 FAULT CODE AUX 11020 ........................................................................................................................ 55-6-17 FAULT CODE AUX 11030 ........................................................................................................................ 55-6-18 FAULT CODE AUX 11040 ........................................................................................................................ 55-6-19 FAULT CODE AUX 11060 ........................................................................................................................ 55-6-20 FAULT CODE AUX 11070 ........................................................................................................................ 55-6-21 FAULT CODE AUX 11080 ........................................................................................................................ 55-6-22 FAULT CODE AUX 11090 ........................................................................................................................ 55-6-23 FAULT CODE AUX 11100 ........................................................................................................................ 55-6-24 FAULT CODE AUX 11110 ........................................................................................................................ 55-6-25 FAULT CODE AUX 12011 ........................................................................................................................ 55-6-26 FAULT CODE AUX 12041 ........................................................................................................................ 55-6-29 FAULT CODE AUX 51011 ........................................................................................................................ 55-6-32 FAULT CODE AUX 51012 ........................................................................................................................ 55-6-33 FAULT CODE AUX 51029 ........................................................................................................................ 55-6-34 FAULT CODE AUX 51031 ........................................................................................................................ 55-6-35 FAULT CODE AUX 51032 ........................................................................................................................ 55-6-36 FAULT CODE AUX 51039 ........................................................................................................................ 55-6-37 FAULT CODE AUX 51041 ........................................................................................................................ 55-6-38 FAULT CODE AUX 51042 ........................................................................................................................ 55-6-39 FAULT CODE AUX 51049 ........................................................................................................................ 55-6-40 FAULT CODE AUX 51053 ........................................................................................................................ 55-6-41 FAULT CODE AUX 51054 ........................................................................................................................ 55-6-42 FAULT CODE AUX 51055 ........................................................................................................................ 55-6-43 FAULT CODE AUX 51056 ........................................................................................................................ 55-6-45 FAULT CODE AUX 51063 ........................................................................................................................ 55-6-47 FAULT CODE AUX 51064 ........................................................................................................................ 55-6-48 FAULT CODE AUX 51065 ........................................................................................................................ 55-6-49
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 27 FAULT CODE AUX 51066 ........................................................................................................................ 55-6-51 FAULT CODE AUX 51073 ........................................................................................................................ 55-6-53 FAULT CODE AUX 51074 ........................................................................................................................ 55-6-54 FAULT CODE AUX 51075 ........................................................................................................................ 55-6-55 FAULT CODE AUX 51076 ........................................................................................................................ 55-6-57 FAULT CODE AUX 51083 ........................................................................................................................ 55-6-59 FAULT CODE AUX 51084 ........................................................................................................................ 55-6-60 FAULT CODE AUX 51085 ........................................................................................................................ 55-6-61 FAULT CODE AUX 51086 ........................................................................................................................ 55-6-63 FAULT CODE AUX 51093 ........................................................................................................................ 55-6-65 FAULT CODE AUX 51094 ........................................................................................................................ 55-6-66 FAULT CODE AUX 51095 ........................................................................................................................ 55-6-67 FAULT CODE AUX 51096 ........................................................................................................................ 55-6-69 FAULT CODE AUX 51101 ........................................................................................................................ 55-6-71 FAULT CODE AUX 51103 ........................................................................................................................ 55-6-72 FAULT CODE AUX 51105 ........................................................................................................................ 55-6-73 FAULT CODE AUX 51107 ........................................................................................................................ 55-6-74 FAULT CODE AUX 51109 ........................................................................................................................ 55-6-75 FAULT CODE AUX 51112 ........................................................................................................................ 55-6-76 FAULT CODE AUX 51114 ........................................................................................................................ 55-6-77 FAULT CODE AUX 51116 ........................................................................................................................ 55-6-78 FAULT CODE AUX 51118 ........................................................................................................................ 55-6-79 FAULT CODE AUX 51121 ........................................................................................................................ 55-6-80 FAULT CODE AUX 51123 ........................................................................................................................ 55-6-81 FAULT CODE AUX 51125 ........................................................................................................................ 55-6-82 FAULT CODE AUX 51127 ........................................................................................................................ 55-6-83 FAULT CODE AUX 51129 ........................................................................................................................ 55-6-84 FAULT CODE AUX 51132 ........................................................................................................................ 55-6-85 FAULT CODE AUX 51134 ........................................................................................................................ 55-6-86 FAULT CODE AUX 51136 ........................................................................................................................ 55-6-87 FAULT CODE AUX 51138 ........................................................................................................................ 55-6-88 FAULT CODE AUX 51141 ........................................................................................................................ 55-6-89 FAULT CODE AUX 51143 ........................................................................................................................ 55-6-90 FAULT CODE AUX 51145 ........................................................................................................................ 55-6-91 FAULT CODE AUX 51147 ........................................................................................................................ 55-6-92 FAULT CODE AUX 51149 ........................................................................................................................ 55-6-93 FAULT CODE AUX 51250 ........................................................................................................................ 55-6-94 FAULT CODE AUX 51261 ........................................................................................................................ 55-6-95 FAULT CODE AUX 51262 ........................................................................................................................ 55-6-96 FAULT CODE AUX 51401 ........................................................................................................................ 55-6-97 FAULT CODE AUX 51402 ........................................................................................................................ 55-6-98 FAULT CODE AUX 51411 ........................................................................................................................ 55-6-99 FAULT CODE AUX 51412 ...................................................................................................................... 55-6-100 FAULT CODE AUX 65535 ...................................................................................................................... 55-6-101
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 28 INSTRUMENTATION CONTROLLER FAULT CODES .................SECTION 55, CHAPTER 7 (Book 8 - 87525649) (TJ 280, 330, 380, 430, 480, and 530 Series and T9010, 20, 30, 40, 50, and 9060 Series Before S/N Z7F204001) FAULT CODE INST 1015 ........................................................................................................................... 55-7-4 FAULT CODE INST 3010 ........................................................................................................................... 55-7-5 FAULT CODE INST 3020 ........................................................................................................................... 55-7-6 FAULT CODE INST 3022 ........................................................................................................................... 55-7-7 FAULT CODE INST 5010 ........................................................................................................................... 55-7-7 FAULT CODE INST 5011 ........................................................................................................................... 55-7-7 FAULT CODE INST 10031 ......................................................................................................................... 55-7-8 FAULT CODE INST 10032 ......................................................................................................................... 55-7-9 FAULT CODE INST 10033 ......................................................................................................................... 55-7-9 FAULT CODE INST 10034 ....................................................................................................................... 55-7-10 FAULT CODE INST 10035 ....................................................................................................................... 55-7-10 FAULT CODE INST 10036 ....................................................................................................................... 55-7-11 FAULT CODE INST 10037 ....................................................................................................................... 55-7-11 FAULT CODE INST 10038 ....................................................................................................................... 55-7-12 FAULT CODE INST 11011 ....................................................................................................................... 55-7-13 FAULT CODE INST 12011 ....................................................................................................................... 55-7-15 FAULT CODE INST 12021 ....................................................................................................................... 55-7-18 FAULT CODE INST 12022 ....................................................................................................................... 55-7-20 FAULT CODE INST 12023 ....................................................................................................................... 55-7-22 FAULT CODE INST 12031 ....................................................................................................................... 55-7-25 FAULT CODE INST 12043 ....................................................................................................................... 55-7-28 FAULT CODE INST 12051 ....................................................................................................................... 55-7-30 FAULT CODE INST 12061 ....................................................................................................................... 55-7-31 FAULT CODE INST 12071 ....................................................................................................................... 55-7-34 FAULT CODE INST 12091 ....................................................................................................................... 55-7-37 FAULT CODE INST 12101 ....................................................................................................................... 55-7-40 FAULT CODE INST 12111 ....................................................................................................................... 55-7-42 FAULT CODE INST 12121 ....................................................................................................................... 55-7-44 FAULT CODE INST 13010 ....................................................................................................................... 55-7-45 FAULT CODE INST 13011 ....................................................................................................................... 55-7-45 FAULT CODE INST 13012 ....................................................................................................................... 55-7-45 FAULT CODE INST 13021 ....................................................................................................................... 55-7-46 FAULT CODE INST 13022 ....................................................................................................................... 55-7-47 FAULT CODE INST 13031 ....................................................................................................................... 55-7-49 FAULT CODE INST 13032 ....................................................................................................................... 55-7-50 FAULT CODE INST 13040 ....................................................................................................................... 55-7-51 FAULT CODE INST 13044 ....................................................................................................................... 55-7-52 FAULT CODE INST 13051 ....................................................................................................................... 55-7-53 FAULT CODE INST 13052 ....................................................................................................................... 55-7-53 FAULT CODE INST 53001 ....................................................................................................................... 55-7-54 FAULT CODE INST 53002 ....................................................................................................................... 55-7-54 FAULT CODE INST 65535 ....................................................................................................................... 55-7-54
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 29 AUX67 CONTROLLER FAULT CODES (FOR REMOTE VALVE SECTIONS 6 & 7)....................................SECTION 55, CHAPTER 8 (Book 8 - 87525649) FAULT CODE AUX67 8012 ........................................................................................................................ 55-8-5 FAULT CODE AUX67 9009 ........................................................................................................................ 55-8-6 FAULT CODE AUX67 9019 ........................................................................................................................ 55-8-7 FAULT CODE AUX67 9029 ........................................................................................................................ 55-8-8 FAULT CODE AUX67 9039 ........................................................................................................................ 55-8-9 FAULT CODE AUX67 11011 .................................................................................................................... 55-8-10 FAULT CODE AUX67 11012 .................................................................................................................... 55-8-11 FAULT CODE AUX67 11021 .................................................................................................................... 55-8-12 FAULT CODE AUX67 11022 .................................................................................................................... 55-8-12 FAULT CODE AUX67 11061 .................................................................................................................... 55-8-14 FAULT CODE AUX67 11062 .................................................................................................................... 55-8-15 FAULT CODE AUX67 11071 .................................................................................................................... 55-8-16 FAULT CODE AUX67 11072 .................................................................................................................... 55-8-17 FAULT CODE AUX67 11081 .................................................................................................................... 55-8-18 FAULT CODE AUX67 11082 .................................................................................................................... 55-8-19 FAULT CODE AUX67 11091 .................................................................................................................... 55-8-20 FAULT CODE AUX67 11092 .................................................................................................................... 55-8-21 FAULT CODE AUX67 11111 .................................................................................................................... 55-8-22 FAULT CODE AUX67 11112 .................................................................................................................... 55-8-23 FAULT CODE AUX67 11121 .................................................................................................................... 55-8-24 FAULT CODE AUX67 11122 .................................................................................................................... 55-8-25 FAULT CODE AUX67 11131 .................................................................................................................... 55-8-26 FAULT CODE AUX67 11132 .................................................................................................................... 55-8-27 FAULT CODE AUX67 11141 .................................................................................................................... 55-8-28 FAULT CODE AUX67 11142 .................................................................................................................... 55-8-29 FAULT CODE AUX67 12022 .................................................................................................................... 55-8-30 FAULT CODE AUX67 12023 .................................................................................................................... 55-8-31 FAULT CODE AUX67 12041 .................................................................................................................... 55-8-32 FAULT CODE AUX67 51011 .................................................................................................................... 55-8-35 FAULT CODE AUX67 51012 .................................................................................................................... 55-8-36 FAULT CODE AUX67 51029 .................................................................................................................... 55-8-37 FAULT CODE AUX67 51039 .................................................................................................................... 55-8-38 FAULT CODE AUX67 51049 .................................................................................................................... 55-8-39 FAULT CODE AUX67 51053 .................................................................................................................... 55-8-40 FAULT CODE AUX67 51054 .................................................................................................................... 55-8-41 FAULT CODE AUX67 51055 .................................................................................................................... 55-8-42 FAULT CODE AUX67 51056 .................................................................................................................... 55-8-43 FAULT CODE AUX67 51063 .................................................................................................................... 55-8-44 FAULT CODE AUX67 51064 .................................................................................................................... 55-8-45 FAULT CODE AUX67 510565 .................................................................................................................. 55-8-46 FAULT CODE AUX67 51066 .................................................................................................................... 55-8-47 FAULT CODE AUX67 51261 .................................................................................................................... 55-8-48 FAULT CODE AUX67 51262 .................................................................................................................... 55-8-49 FAULT CODE AUX67 51301 .................................................................................................................... 55-8-50 FAULT CODE AUX67 51302 .................................................................................................................... 55-8-51 FAULT CODE AUX67 51401 .................................................................................................................... 55-8-52 FAULT CODE AUX67 51402 .................................................................................................................... 55-8-53 FAULT CODE AUX67 51509 .................................................................................................................... 55-8-54 FAULT CODE AUX67 65535 .................................................................................................................... 55-8-55
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 30 BATTERY SERVICING AND TESTING.........................................SECTION 55, CHAPTER 9 (Book 8 - 87525649) SAFETY RULES ......................................................................................................................................... 55-9-3 SPECIFICATIONS ...................................................................................................................................... 55-9-4 ACCESS TO BATTERIES .......................................................................................................................... 55-9-5 TJ280/330 and T9010/9020 Tractors ........................................................................................................ 55-9-5 TJ380/430/480/530 and T9030/40/50/60 Tractors .................................................................................... 55-9-6 REMOVAL AND INSTALLATION OF BATTERIES .................................................................................... 55-9-7 To remove batteries .................................................................................................................................. 55-9-7 To install batteries ..................................................................................................................................... 55-9-7 BATTERY MAINTENANCE ........................................................................................................................ 55-9-7 Electrolyte Level ........................................................................................................................................ 55-9-7 Inspecting And Cleaning A Battery ........................................................................................................... 55-9-7 Battery Condition Check ........................................................................................................................... 55-9-8 Specific Gravity Check .............................................................................................................................. 55-9-8 Procedure ................................................................................................................................................ 55-9-10 Three Minute Charge Test ...................................................................................................................... 55-9-11 Testing Battery Cells With Cadmium Probes .......................................................................................... 55-9-12 Battery Leakage Test .............................................................................................................................. 55-9-14 Battery Fast Charging ............................................................................................................................. 55-9-14 Battery Charging ..................................................................................................................................... 55-9-15 Activating Charged Batteries..................................................................................................................... 55-9-15 TRANSMISSION CONTROLLER FAULT CODES .......................SECTION 55, CHAPTER 10 (Book 9 - 84257313 (T9020, 30, 40, 50, and 9060 Series After S/N Z7F204001) FAULT CODE TRANS 11 ......................................................................................................................... 55-10-4 FAULT CODE TRANS 12 ......................................................................................................................... 55-10-5 FAULT CODE TRANS 24 ......................................................................................................................... 55-10-6 FAULT CODE TRANS 37 ......................................................................................................................... 55-10-7 FAULT CODE TRANS 38 ......................................................................................................................... 55-10-8 FAULT CODE TRANS 47 ......................................................................................................................... 55-10-9 FAULT CODE TRANS 48 ....................................................................................................................... 55-10-11 FAULT CODE TRANS 50 ....................................................................................................................... 55-10-12 FAULT CODE TRANS 51 ....................................................................................................................... 55-10-13 FAULT CODE TRANS 52 ....................................................................................................................... 55-10-14 FAULT CODE TRANS 53 ....................................................................................................................... 55-10-15 FAULT CODE TRANS 54 ....................................................................................................................... 55-10-17 FAULT CODE TRANS 59 ....................................................................................................................... 55-10-19 FAULT CODE TRANS 60 ....................................................................................................................... 55-10-20 FAULT CODE TRANS 66 ....................................................................................................................... 55-10-22 FAULT CODE TRANS 67 ....................................................................................................................... 55-10-23 FAULT CODE TRANS 68 ....................................................................................................................... 55-10-24 FAULT CODE TRANS 69 ....................................................................................................................... 55-10-25 FAULT CODE TRANS 70 ....................................................................................................................... 55-10-26 FAULT CODE TRANS 73 ....................................................................................................................... 55-10-27 FAULT CODE TRANS 74 ....................................................................................................................... 55-10-28 FAULT CODE TRANS 75 ....................................................................................................................... 55-10-29 FAULT CODE TRANS 76 ....................................................................................................................... 55-10-30 FAULT CODE TRANS 77 ....................................................................................................................... 55-10-31 FAULT CODE TRANS 80 ....................................................................................................................... 55-10-32 FAULT CODE TRANS 81 ....................................................................................................................... 55-10-34 FAULT CODE TRANS 83 ....................................................................................................................... 55-10-36 FAULT CODE TRANS 103 ..................................................................................................................... 55-10-37 FAULT CODE TRANS 104 ..................................................................................................................... 55-10-38 FAULT CODE TRANS 105 ..................................................................................................................... 55-10-39 FAULT CODE TRANS 106 ..................................................................................................................... 55-10-40 FAULT CODE TRANS 107 ..................................................................................................................... 55-10-41 FAULT CODE TRANS 108 ..................................................................................................................... 55-10-42
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 31 FAULT CODE TRANS 109 ..................................................................................................................... 55-10-43 FAULT CODE TRANS 110 ..................................................................................................................... 55-10-44 FAULT CODE TRANS 111 ..................................................................................................................... 55-10-45 FAULT CODE TRANS 112 ..................................................................................................................... 55-10-46 FAULT CODE TRANS 113 ..................................................................................................................... 55-10-47 FAULT CODE TRANS 114 ..................................................................................................................... 55-10-48 FAULT CODE TRANS 115 ..................................................................................................................... 55-10-49 FAULT CODE TRANS 116 ..................................................................................................................... 55-10-50 FAULT CODE TRANS 117 ..................................................................................................................... 55-10-51 FAULT CODE TRANS 118 ..................................................................................................................... 55-10-52 FAULT CODE TRANS 119 ..................................................................................................................... 55-10-53 FAULT CODE TRANS 120 ..................................................................................................................... 55-10-54 FAULT CODE TRANS 122 ..................................................................................................................... 55-10-55 FAULT CODE TRANS 123 ..................................................................................................................... 55-10-56 FAULT CODE TRANS 125 ..................................................................................................................... 55-10-57 FAULT CODE TRANS 126 ..................................................................................................................... 55-10-58 FAULT CODE TRANS 127 ..................................................................................................................... 55-10-59 FAULT CODE TRANS 128 ..................................................................................................................... 55-10-60 FAULT CODE TRANS 129 ..................................................................................................................... 55-10-61 FAULT CODE TRANS 130 ..................................................................................................................... 55-10-62 FAULT CODE TRANS 131 ..................................................................................................................... 55-10-63 FAULT CODE TRANS 132 ..................................................................................................................... 55-10-64 FAULT CODE TRANS 133 ..................................................................................................................... 55-10-65 FAULT CODE TRANS 135 ..................................................................................................................... 55-10-66 FAULT CODE TRANS 136 ..................................................................................................................... 55-10-68 FAULT CODE TRANS 137 ..................................................................................................................... 55-10-70 FAULT CODE TRANS 139 ..................................................................................................................... 55-10-71 FAULT CODE TRANS 140 ..................................................................................................................... 55-10-72 FAULT CODE TRANS 141 ..................................................................................................................... 55-10-73 FAULT CODE TRANS 143 ..................................................................................................................... 55-10-74 FAULT CODE TRANS 144 ..................................................................................................................... 55-10-75 FAULT CODE TRANS 145 ..................................................................................................................... 55-10-76 FAULT CODE TRANS 146 ..................................................................................................................... 55-10-77 FAULT CODE TRANS 147 ..................................................................................................................... 55-10-78 FAULT CODE TRANS 148 ..................................................................................................................... 55-10-80 ARMREST CONTROLLER FAULT CODES ................................SECTION 55, CHAPTER 11 (Book 9 - 84257313) (T9020, 30, 40, 50, and 9060 Series After S/N Z7F204001) FAULT CODE ARM 19 ............................................................................................................................. 55-11-4 FAULT CODE ARM 29 ............................................................................................................................. 55-11-5 FAULT CODE ARM 39 ............................................................................................................................. 55-11-6 FAULT CODE ARM 49 ............................................................................................................................. 55-11-7 FAULT CODE ARM 59 ............................................................................................................................. 55-11-9 FAULT CODE ARM 69 ........................................................................................................................... 55-11-10 FAULT CODE ARM 79 ........................................................................................................................... 55-11-11 FAULT CODE ARM 89 ........................................................................................................................... 55-11-12 FAULT CODE ARM 99 ........................................................................................................................... 55-11-13 FAULT CODE ARM 109 ......................................................................................................................... 55-11-14 FAULT CODE ARM 119 ......................................................................................................................... 55-11-15 FAULT CODE ARM 129 ......................................................................................................................... 55-11-16 FAULT CODE ARM 139 ......................................................................................................................... 55-11-17 FAULT CODE ARM 149 ......................................................................................................................... 55-11-18 FAULT CODE ARM 159 ......................................................................................................................... 55-11-19 FAULT CODE ARM 169 ......................................................................................................................... 55-11-20 FAULT CODE ARM 1019 ....................................................................................................................... 55-11-21 FAULT CODE ARM 1029 ....................................................................................................................... 55-11-22 FAULT CODE ARM 1039 ....................................................................................................................... 55-11-23
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 32 FAULT CODE ARM 1049 ....................................................................................................................... 55-11-24 FAULT CODE ARM 1059 ....................................................................................................................... 55-11-25 FAULT CODE ARM 1069 ....................................................................................................................... 55-11-26 FAULT CODE ARM 1079 ....................................................................................................................... 55-11-27 FAULT CODE ARM 1109 ....................................................................................................................... 55-11-28 FAULT CODE ARM 1119 ....................................................................................................................... 55-11-29 FAULT CODE ARM 1129 ....................................................................................................................... 55-11-30 FAULT CODE ARM 1139 ....................................................................................................................... 55-11-31 FAULT CODE ARM 1149 ....................................................................................................................... 55-11-32 FAULT CODE ARM 8011 ....................................................................................................................... 55-11-33 FAULT CODE ARM 9011 ....................................................................................................................... 55-11-34 FAULT CODE ARM 9012 ....................................................................................................................... 55-11-35 FAULT CODE ARM 9013 ....................................................................................................................... 55-11-36 FAULT CODE ARM 9014 ....................................................................................................................... 55-11-37 FAULT CODE ARM 9015 ....................................................................................................................... 55-11-38 FAULT CODE ARM 9021 ....................................................................................................................... 55-11-39 FAULT CODE ARM 9031 ....................................................................................................................... 55-11-40 FAULT CODE ARM 9041 ....................................................................................................................... 55-11-41 FAULT CODE ARM 10091 ..................................................................................................................... 55-11-42 FAULT CODE ARM 12013 ..................................................................................................................... 55-11-43 FAULT CODE ARM 12081 ..................................................................................................................... 55-11-45 FAULT CODE ARM 65535 ..................................................................................................................... 55-11-47 INSTRUMENTATION CONTROLLER FAULT CODES ................SECTION 55, CHAPTER 12 (Book 9 - 84257313 (T9020, 30, 40, 50, and 9060 Series After S/N Z7F204001) FAULT CODE INST 1015 ......................................................................................................................... 55-12-5 FAULT CODE INST 1024 ......................................................................................................................... 55-12-6 FAULT CODE INST 1034 ......................................................................................................................... 55-12-7 FAULT CODE INST 1044 ......................................................................................................................... 55-12-8 FAULT CODE INST 3010 ......................................................................................................................... 55-12-9 FAULT CODE INST 3020 ....................................................................................................................... 55-12-10 FAULT CODE INST 3022 ....................................................................................................................... 55-12-11 FAULT CODE INST 5010 ....................................................................................................................... 55-12-12 FAULT CODE INST 5011 ....................................................................................................................... 55-12-13 FAULT CODE INST 7034 ....................................................................................................................... 55-12-14 FAULT CODE INST 10031 ..................................................................................................................... 55-12-15 FAULT CODE INST 10032 ..................................................................................................................... 55-12-16 FAULT CODE INST 10033 ..................................................................................................................... 55-12-17 FAULT CODE INST 10034 ..................................................................................................................... 55-12-18 FAULT CODE INST 10035 ..................................................................................................................... 55-12-19 FAULT CODE INST 10036 ..................................................................................................................... 55-12-20 FAULT CODE INST 10037 ..................................................................................................................... 55-12-21 FAULT CODE INST 10038 ..................................................................................................................... 55-12-22 FAULT CODE INST 11011 ..................................................................................................................... 55-12-23 FAULT CODE INST 11021 ..................................................................................................................... 55-12-24 FAULT CODE INST 11022 ..................................................................................................................... 55-12-25 FAULT CODE INST 12011 ..................................................................................................................... 55-12-26 FAULT CODE INST 12021 ..................................................................................................................... 55-12-29 FAULT CODE INST 12022 ..................................................................................................................... 55-12-31 FAULT CODE INST 12023 ..................................................................................................................... 55-12-33 FAULT CODE INST 12031 ..................................................................................................................... 55-12-36 FAULT CODE INST 12043 ..................................................................................................................... 55-12-39 FAULT CODE INST 12051 ..................................................................................................................... 55-12-41 FAULT CODE INST 12061 ..................................................................................................................... 55-12-42 FAULT CODE INST 12071 ..................................................................................................................... 55-12-45 FAULT CODE INST 12091 ..................................................................................................................... 55-12-48 FAULT CODE INST 12101 ..................................................................................................................... 55-12-51
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 33 FAULT CODE INST 12111 ..................................................................................................................... 55-12-53 FAULT CODE INST 12121 ..................................................................................................................... 55-12-55 FAULT CODE INST 13010 ..................................................................................................................... 55-12-56 FAULT CODE INST 13011 ..................................................................................................................... 55-12-57 FAULT CODE INST 13012 ..................................................................................................................... 55-12-58 FAULT CODE INST 13021 ..................................................................................................................... 55-12-59 FAULT CODE INST 13022 ..................................................................................................................... 55-12-60 FAULT CODE INST 13031 ..................................................................................................................... 55-12-62 FAULT CODE INST 13032 ..................................................................................................................... 55-12-63 FAULT CODE INST 13033 ..................................................................................................................... 55-12-65 FAULT CODE INST 13034 ..................................................................................................................... 55-12-66 FAULT CODE INST 13040 ..................................................................................................................... 55-12-67 FAULT CODE INST 13044 ..................................................................................................................... 55-12-68 FAULT CODE INST 13051 ..................................................................................................................... 55-12-69 FAULT CODE INST 13052 ..................................................................................................................... 55-12-70 FAULT CODE INST 53001 ..................................................................................................................... 55-12-71 FAULT CODE INST 53002 ..................................................................................................................... 55-12-72 FAULT CODE INST 53005 ..................................................................................................................... 55-12-73 FAULT CODE INST 65535 ..................................................................................................................... 55-12-74 CAB REMOVAL - TJ280/330 .........................................................SECTION 90, CHAPTER 1 (Book 8 - 87525649) SPECIAL TOOLS ........................................................................................................................................ 90-1-3 SPECIAL TORQUE VALUES ..................................................................................................................... 90-1-3 CAB REMOVAL .......................................................................................................................................... 90-1-4 CAB INSTALLATION ................................................................................................................................ 90-1-11 CAB REMOVAL - TJ380/430/480/530 ...........................................SECTION 90, CHAPTER 2 (Book 8 - 87525649) SPECIAL TOOLS ........................................................................................................................................ 90-2-3 SPECIAL TORQUE VALUES ..................................................................................................................... 90-2-3 CAB REMOVAL .......................................................................................................................................... 90-2-4 CAB INSTALLATION ................................................................................................................................ 90-2-13 HOOD REMOVAL AND INSTALLATION - TJ280/330...................SECTION 90, CHAPTER 3 (Book 8 - 87525649) SPECIAL TORQUE VALUES ..................................................................................................................... 90-3-2 RECOMMENDED TOOLS .......................................................................................................................... 90-3-2 HOOD REMOVAL ....................................................................................................................................... 90-3-3 HOOD INSTALLATION ............................................................................................................................... 90-3-5 HOOD REMOVAL AND INSTALLATION - TJ480/530...................SECTION 90, CHAPTER 4 (Book 8 - 87525649) SPECIAL TORQUE VALUES ..................................................................................................................... 90-4-2 RECOMMENDED TOOLS .......................................................................................................................... 90-4-2 HOOD REMOVAL ...................................................................................................................................... 90-4-3 HOOD INSTALLATION ............................................................................................................................... 90-4-5 HOOD REMOVAL AND INSTALLATION - TJ380/430...................SECTION 90, CHAPTER 5 (Book 8 - 87525649) SPECIAL TORQUE VALUES ..................................................................................................................... 90-5-2 RECOMMENDED TOOLS .......................................................................................................................... 90-5-2 HOOD REMOVAL ....................................................................................................................................... 90-5-3 HOOD INSTALLATION ............................................................................................................................... 90-5-6 CAB TOP REMOVAL AND INSTALLATION..................................SECTION 90, CHAPTER 6 (Book 8 - 87525649) CAB TOP REMOVAL ................................................................................................................................. 90-6-3 CAB TOP INSTALLATION .......................................................................................................................... 90-6-5
TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 34 CAB REMOVAL, T9030, 9040, 9050, and 9060 TRACTORS S/N Z7F204001 AND AFTER................................. SECTION 90, CHAPTER 7 (Book 7A - 87740919) SPECIAL TOOLS ........................................................................................................................................ 90-7-3 SPECIAL TORQUE VALUES ..................................................................................................................... 90-7-3 CAB REMOVAL .......................................................................................................................................... 90-7-4 General Information .................................................................................................................................. 90-7-4 CAB INSTALLATION ................................................................................................................................ 90-7-15
Section 10 - Engine - Chapter 1 10-1-4 ENGINE REMOVAL STEP 1 1. Park the tractor on a hard level surface. 2. Place the shift lever in PARK (Powershift) or place the shift levers in neutral. 3. Shut off the engine and remove the key from the switch. 4. If necessary, drain the oil from the engine crankcase. STEP 2 See Hood Removal And Installation in this manual and remove the hood from the tractor. STEP 3 See A/C Component Service for instructions to discharge the air conditioning system. STEP 4 See Radiator, Coolers And Condenser Removal And Installation in this manual for instructions to drain and remove the radiator and cooler assembly. STEP 5 MD05M069 Open the battery access door and remove the negative battery cables from the three batteries. STEP 6 MD05N084 Loosen the air cleaner outlet flex tube clamps. STEP 7 MD05N086 Loosen the turbo inlet elbow clamp. STEP 8 MD05N085 Remove the U-clamp (1) from the air cleaner to turbo inlet tube assembly (2). Remove the assembly from the tractor. 2 12
Section 10 - Engine - Chapter 1 10-1-5 STEP 9 MD05N087 Open the six latches (1) and remove the air cleaner cover (2) and air filter. STEP 10 MD05N089 Remove the heat shield rear mounting bolt. STEP 11 MD05N088 Remove the heat shield two front mounting bolts (1) and nuts. Remove the heat shield assembly (2). STEP 12 MD05N090 Remove the exhaust pipe U-clamp assembly. STEP 13 MD05N092 Loosen the exhaust pipe band clamp. STEP 14 MD05N091 Loosen the turbo exhaust flex tube clamp (1) and remove the flex tube/exhaust pipe assembly (2). 1 2 1 2 1 2
Section 10 - Engine - Chapter 1 10-1-6 STEP 15 MD05N093 Loosen the air cleaner inlet coupler clamps (1) and move the coupler (2) up and off the air cleaner housing (3). STEP 16 MD05N095 Loosen the hose clamps (1) and remove the aspirator tube (2) from the check valve and air cleaner housing. STEP 17 MD05N094 Remove the three RH and three LH air cleaner mounting bolts and remove the air cleaner housing. STEP 18 MD05N097 Remove the bolt, washers and nut from the P-clamp on the rear of the RH inside frame platform. STEP 19 MD05N098 Remove the nut from the platform brace carriage bolt. STEP 20 MD05N096 Remove the three platform to frame mounting bolts, washers and nuts. Remove the platform from the tractor. 1 2 3 1 2 1 1
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
Section 10 - Engine - Chapter 1 10-1-7 STEP 21 MD05N102 Remove the nut bolt and washer and remove the platform brace. NOTE: It is not necessary to remove the brace to remove the engine, but it will allow easier access to other components. STEP 22 MD05N103 Remove the two deaeration hoses (1) from the tank and remove the P-clamp (2) from the hood support frame. Remove the make up hose (3) from the tank. STEP 23 MD05N056 Remove the overflow hose (1) from the deaeration tank. Remove the hose P-clamp (2) from the tank base. STEP 24 MD05N105 Install lifting straps (1) on the hood support assembly as shown. Attach the straps to an overhead hoist (2) and support the assembly. STEP 25 MD05N100 Mark the position of the bracket on the frame. Remove the two LH front hood support bracket mounting bolts, washers and nuts. 1 1 3 2 1 2 2 1 1 1
Section 10 - Engine - Chapter 1 10-1-8 STEP 26 MD05N101 Mark the position of the bracket on the frame. Remove the two LH rear support bracket mounting bolts and washers. STEP 27 MD05N099 Mark the position of the bracket on the frame. Remove the two RH support bracket mounting bolts, washers and nuts. Remove the hood support assembly from the tractor. STEP 28 MD05N106 Install clamps on the heater hoses. STEP 29 MD05N107 Remove the heater hoses from the engne. STEP 30 MD05N108 Install a clamp (1) on the fuel return hose and remove the hose from the engine (2). STEP 31 MD05N109 Remove the engine wire harness connector from the front frame harness. 1 2
Section 10 - Engine - Chapter 1 10-1-9 STEP 32 MD05N110 Remove the two A/C hoses from the compressor. Install plugs in the hose ends and caps on the compressor ports. STEP 33 MD05N111 Carefully move the A/C hoses away from the engine and secure the hoses to the RH trash screen brace. STEP 34 MD05N112 Remove the A/C clutch wire connector (1) from the engine wire harness. Remove the top rear compressor mounting bolt (2) and remove the ground wire (3) from the bolt (2). Install the bolt (2). STEP 35 MD05N114 Remove the alternator wire P-clamp from the engine. STEP 36 MD05N113 Remove the battery cable (1) and exciter wire (2) from the alternator. STEP 37 MD05N115 Remove the heater grid solenoid coil wire connector from the solenoid. 2 3 1 1 2

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New holland t9030 series tractor service repair manual

  • 1. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 1 THIS MANUAL, 84257310, COVERS THE FOLLOWING TRACTORS: TJ 280, 330, 380, 430, 480, and 530 Series T9010, 9020, 9030, 9040, 9050, and 9060 Series T9020, 9030, 9040, 9050, and 9060 Series After S/N Z7F204001 NOTE: Engine repair information is not contained within this tractor Service Manual. For engine repair, refer to appropriate engine service manual as follows: 87515682 - For 8.3 & 9.0L 6 Cylinder, 24 Valve CNH Engine with High Pressure Common Rail Fuel System. 87523643 - For 12.9L 6 Cylinder, Engine. 87737594 - For 12.9L 6 Cylinder, Turbo Compound Engine. STANDARD TORQUE SPECIFICATION.......................................SECTION 00, CHAPTER 1 (Book 1 - 87525642) SAFETY..........................................................................................SECTION 00, CHAPTER 2 (Book 1 - 87525642) LUBRICATION AND MAINTENANCE............................................SECTION 00, CHAPTER 3 (Book 1 - 87525642) ENGINE LUBRICATION ............................................................................................................................. 00-3-3 Engine Oil Selection .................................................................................................................................. 00-3-3 Synthetic Lubricants .................................................................................................................................. 00-3-3 Engine Oil Viscosity/Temperature Usage Recommendation .................................................................... 00-3-3 Engine Coolant Solutions .......................................................................................................................... 00-3-4 LUBRICANTS AND CAPACITIES .............................................................................................................. 00-3-5 LUBRICATION AND MAINTENANCE CHART ........................................................................................... 00-3-6 SPECIFICATIONS..........................................................................SECTION 00, CHAPTER 4 (Book 1 - 87525642) DIESEL ENGINE ........................................................................................................................................ 00-4-3 ENGINE LUBRICATION SYSTEM ............................................................................................................. 00-4-3 FUEL SYSTEM ........................................................................................................................................... 00-4-3 AIR INTAKE SYSTEM ................................................................................................................................ 00-4-3 TRANSMISSION - POWER SHIFT ............................................................................................................ 00-4-4 TRANSMISSION - MANUAL SHIFT ........................................................................................................... 00-4-4 BRAKES ..................................................................................................................................................... 00-4-4 AXLE DIFFERENTIAL AAND FINAL DRIVES ............................................................................................ 00-4-4 POWER TAKEOFF (IF EQUIPPED) ........................................................................................................... 00-4-4 HYDRAULIC SYSTEM ............................................................................................................................... 00-4-5 MEGAFLOW HYDRAULICS (IF EQUIPPED) ............................................................................................. 00-4-5 HITCH SYSTEM (IF EQUIPPED) ............................................................................................................... 00-4-5 DRAWBAR .................................................................................................................................................. 00-4-5 TRACTOR WEIGHTS ................................................................................................................................. 00-4-6 Approximate Base Shipping Weights ........................................................................................................ 00-4-6 Approximate Component Weights ............................................................................................................ 00-4-6 MAXIMUM TRACTOR OPERATING WEIGHT ........................................................................................... 00-4-6 ENGINE REMOVAL AND INSTALLATION - TJ380/430 TRACTORS..................................................................SECTION 10, CHAPTER 1 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-1-3 RECOMMENDED TOOLS .......................................................................................................................... 10-1-3 ENGINE REMOVAL .................................................................................................................................... 10-1-4 ENGINE INSTALLATION .......................................................................................................................... 10-1-13
  • 2. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 2 ENGINE REMOVAL AND INSTALLATION - TJ280/330 TRACTORS..................................................................SECTION 10, CHAPTER 2 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-2-2 SPECIAL TOOLS ........................................................................................................................................ 10-2-2 ENGINE REMOVAL ................................................................................................................................... 10-2-3 ENGINE INSTALLATION ......................................................................................................................... 10-2-10 ENGINE REMOVAL AND INSTALLATION - TJ480/530 TRACTORS..................................................................SECTION 10, CHAPTER 3 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-3-2 RECOMMENDED TOOLS .......................................................................................................................... 10-3-2 ENGINE REMOVAL .................................................................................................................................... 10-3-3 ENGINE INSTALLATION .......................................................................................................................... 10-3-13 AIR INDUCTION SYSTEM - TJ380/430 TRACTORS....................SECTION 10, CHAPTER 4 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-4-2 AIR INDUCTION SYSTEM ......................................................................................................................... 10-4-3 AIR INDUCTION SYSTEM DESCRIPTION ................................................................................................ 10-4-4 AIR INDUCTION SYSTEM ......................................................................................................................... 10-4-4 AIR FILTER ELEMENTS ............................................................................................................................ 10-4-4 PRIMARY AND SECONDARY FILTER ELEMENT REMOVAL ............................................................... 10-4-5 PRIMARY FILTER ELEMENT SERVICE .................................................................................................. 10-4-7 RESTRICTION INDICATOR SWITCH REMOVAL AND TEST .................................................................. 10-4-8 AIR CLEANER HOUSING REMOVAL ........................................................................................................ 10-4-9 ASPIRATOR STRATA TUBE CLEANING ............................................................................................... 10-4-10 ASPIRATOR SAFETY CHECK VALVE REMOVAL AND TEST ............................................................... 10-4-11 ASPIRATOR SAFETY VALVE INSTALLATION ....................................................................................... 10-4-11 AIR CLEANER HOUSING INSTALLATION .............................................................................................. 10-4-12 RESTRICTION INDICATOR SWITCH INSTALLATION ........................................................................... 10-4-13 SECONDARY AND PRIMARY FILTER ELEMENT INSTALLATION ....................................................... 10-4-13 AIR INDUCTION SYSTEM - TJ280/330 TRACTORS....................SECTION 10, CHAPTER 5 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-5-3 AIR INDUCTION SYSTEM ........................................................................................................................ 10-5-4 AIR FILTER ELEMENTS ............................................................................................................................ 10-5-4 ENGINE AIR INDUCTION SYSTEM .......................................................................................................... 10-5-5 Primary And Secondary Filter Element Removal ...................................................................................... 10-5-5 PRIMARY FILTER ELEMENT SERVICE ................................................................................................... 10-5-7 RESTRICTION INDICATOR SWITCH REMOVAL AND TEST .................................................................. 10-5-7 AIR CLEANER HOUSING REMOVAL ........................................................................................................ 10-5-8 Aspirator Strata Tube Cleaning ............................................................................................................... 10-5-10 ASPIRATOR SAFETY CHECK VALVE REMOVAL AND TEST ............................................................. 10-5-12 ASPIRATOR SAFETY CHECK VALVE INSTALLATION ......................................................................... 10-5-13 AIR CLEANER HOUSING INSTALLATION .............................................................................................. 10-5-14 RESTRICTION INDICATOR SWITCH INSTALLATION ........................................................................... 10-5-15 SECONDARY AND PRIMARY FILTER ELEMENT INSTALLATION ....................................................... 10-5-16 AIR INDUCTION SYSTEM - TJ480/530 TRACTORS....................SECTION 10, CHAPTER 6 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-6-2 AIR INDUCTION SYSTEM ......................................................................................................................... 10-6-3 AIR FILTER ELEMENTS ............................................................................................................................ 10-6-4 Primary And Secondary Filter Element Removal ...................................................................................... 10-6-5 PRIMARY FILTER ELEMENT SERVICE ................................................................................................... 10-6-7 RESTRICTION INDICATOR SWITCH REMOVAL AND TEST .................................................................. 10-6-8 AIR CLEANER HOUSING REMOVAL ........................................................................................................ 10-6-9 ASPIRATOR STRATA TUBE CLEANING ............................................................................................... 10-6-10 ASPIRATOR SAFETY CHECK VALVE REMOVAL AND TEST ............................................................... 10-6-11
  • 3. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 3 ASPIRATOR SAFETY VALVE INSTALLATION ....................................................................................... 10-6-11 AIR CLEANER HOUSING INSTALLATION .............................................................................................. 10-6-12 RESTRICTION INDICATOR SWITCH INSTALLATION ........................................................................... 10-6-13 SECONDARY AND PRIMARY FILTER ELEMENT INSTALLATION ....................................................... 10-6-13 VISCOUS FAN DRIVE - TJ280/330/380/430, HYD FAN DRIVE TEST - TJ480/530 .............................................SECTION 10, CHAPTER 7 (Book 1 - 87525642) VISCOUS FAN DRIVE TEST - TJ280, TJ330, TJ380, TJ430 .................................................................... 10-7-3 HYDRAULIC FAN DRIVE TEST - TJ480, TJ530 ........................................................................................ 10-7-5 RADIATOR, COOLERS AND CONDENSER REMOVE/INSTALL - TJ280/330 ....................................................SECTION 10, CHAPTER 8 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-8-2 GENERAL INFORMATION ........................................................................................................................ 10-8-3 FUEL COOLER REMOVAL ........................................................................................................................ 10-8-3 FUEL COOLER INSTALLATION ................................................................................................................ 10-8-4 ENGINE AIR TO AIR COOLER REMOVAL .............................................................................................. 10-8-6 AIR TO AIR COOLER INSTALLATION ...................................................................................................... 10-8-9 A/C CONDENSER REMOVAL ................................................................................................................ 10-8-12 A/C CONDENSER INSTALLATION ........................................................................................................ 10-8-13 HYDRAULIC/TRANSMISSION OIL COOLER REMOVAL ..................................................................... 10-8-15 HYDRAULIC/TRANSMISSION OIL COOLER INSTALLATION ............................................................... 10-8-17 RADIATOR AND COOLER ASSEMBLY REMOVAL ............................................................................... 10-8-20 RADIATOR AND COOLER ASSEMBLY INSTALLATION ........................................................................ 10-8-27 RADIATOR, COOLERS AND CONDENSER REMOVE/INSTALL - TJ480/530 ....................................................SECTION 10, CHAPTER 9 (Book 1 - 87525642) SPECIAL TORQUE VALUES ..................................................................................................................... 10-9-3 GENERAL INFORMATION ......................................................................................................................... 10-9-3 FUEL COOLER REMOVAL ........................................................................................................................ 10-9-4 FUEL COOLER INSTALLATION ................................................................................................................ 10-9-4 ENGINE AIR TO AIR COOLER REMOVAL ............................................................................................... 10-9-5 ENGINE AIR TO AIR COOLER INSTALLATION ....................................................................................... 10-9-7 A/C CONDENSER AND HYDRAULIC FAN COOLER REMOVAL ............................................................. 10-9-9 A/C CONDENSER AND HYDRAULIC FAN COOLER INSTALLATION ................................................... 10-9-10 RADIATOR AND COOLER ASSEMBLY REMOVAL ................................................................................ 10-9-12 RADIATOR/COOLER DISASSEMBLY ..................................................................................................... 10-9-19 RADIATOR, COOLERS AND CONDENSER REMOVE/INSTALL - TJ380/430 ..................................................SECTION 10, CHAPTER 10 (Book 1 - 87525642) SPECIAL TORQUE VALUES ................................................................................................................... 10-10-2 GENERAL INFORMATION ...................................................................................................................... 10-10-3 ENGINE AIR TO AIR COOLER REMOVAL ............................................................................................ 10-10-4 AIR TO AIR COOLER INSTALLATION .................................................................................................... 10-10-6 A/C CONDENSER REMOVAL ................................................................................................................ 10-10-7 A/C CONDENSER INSTALLATION ........................................................................................................ 10-10-8 HYDRAULIC/TRANSMISSION OIL COOLER REMOVAL ................................................................... 10-10-10 HYDRAULIC/TRANSMISSION OIL COOLER INSTALLATION ............................................................. 10-10-12 RADIATOR AND COOLER ASSEMBLY REMOVAL ............................................................................. 10-10-15
  • 4. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 4 AIR INDUCTION SYSTEM, T9030, 9040 and 9050 Tractors, S/N Z7F204001 and After.......................................................... SECTION 10, CHAPTER 11 (Book 1A - 87740915) SPECIAL TORQUE VALUES ................................................................................................................... 10-11-2 AIR INDUCTION SYSTEM ....................................................................................................................... 10-11-3 AIR INDUCTION SYSTEM DESCRIPTION .............................................................................................. 10-11-4 AIR INDUCTION SYSTEM ....................................................................................................................... 10-11-4 AIR FILTER ELEMENTS .......................................................................................................................... 10-11-4 PRIMARY AND SECONDARY FILTER ELEMENT REMOVAL ............................................................. 10-11-5 PRIMARY FILTER ELEMENT SERVICE ................................................................................................ 10-11-7 RESTRICTION INDICATOR SWITCH REMOVAL AND TEST ................................................................ 10-11-8 AIR CLEANER HOUSING REMOVAL ...................................................................................................... 10-11-9 ASPIRATOR STRATA TUBE CLEANING ............................................................................................. 10-11-11 ASPIRATOR SAFETY CHECK VALVE REMOVAL AND TEST ............................................................. 10-11-12 ASPIRATOR SAFETY VALVE INSTALLATION ..................................................................................... 10-11-12 AIR CLEANER HOUSING INSTALLATION ............................................................................................ 10-11-13 RESTRICTION INDICATOR SWITCH INSTALLATION ......................................................................... 10-11-14 SECONDARY AND PRIMARY FILTER ELEMENT INSTALLATION ..................................................... 10-11-15 ENGINE REMOVAL AND INSTALLATION, T9050 TRACTOR, S/N Z7F204001 AND AFTER ..................... SECTION 10, CHAPTER 12 (Book 1A - 87740915) SPECIAL TORQUE VALUES ................................................................................................................... 10-12-3 RECOMMENDED TOOLS ........................................................................................................................ 10-12-3 ENGINE REMOVAL .................................................................................................................................. 10-12-4 ENGINE INSTALLATION ........................................................................................................................ 10-12-15 RADIATOR, COOLERS AND CONDENSER REMOVE AND INSTALL, T9050 TRACTOR ............................ SECTION 10, CHAPTER 13 (Book 1A - 87740915) SPECIAL TORQUE VALUES ................................................................................................................... 10-13-3 ENGINE AIR TO AIR COOLER REMOVAL ............................................................................................. 10-13-4 ENGINE AIR TO AIR COOLER INSTALLATION ..................................................................................... 10-13-6 A/C CONDENSER AND HYDRAULIC FAN COOLER REMOVAL ........................................................... 10-13-8 A/C CONDENSER AND HYDRAULIC FAN COOLER INSTALLATION ................................................... 10-13-9 RADIATOR AND COOLER ASSEMBLY REMOVAL .............................................................................. 10-13-11 RADIATOR/COOLER DISASSEMBLY ................................................................................................... 10-13-18 POWERSHIFT TRANSMISSION REMOVE/INSTALL - TJ280/330.......................................................................................SECTION 21, CHAPTER 1 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-1-2 SPECIAL TOOLS ........................................................................................................................................ 21-1-2 TRANSMISSION REMOVAL ..................................................................................................................... 21-1-3 TRANSMISSION INSTALLATION ............................................................................................................. 21-1-9 POWERSHIFT TRANSMISSION REMOVE/INSTALL - TJ380/430/480/530.........................................................................SECTION 21, CHAPTER 2 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-2-3 SPECIAL TOOLS ........................................................................................................................................ 21-2-3 TRANSMISSION REMOVAL ..................................................................................................................... 21-2-4 TRANSMISSION INSTALLATION ........................................................................................................... 21-2-10 ENGINE/TRANSMISSION DRIVE COUPLER REMOVE/INSTALL - TJ280/330 ....................................................SECTION 21, CHAPTER 3 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-3-2 DRIVE COUPLER REMOVAL .................................................................................................................... 21-3-3 DRIVE COUPLER INSTALLATION ............................................................................................................ 21-3-5
  • 5. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 5 ENGINE/TRANSMISSION DRIVE COUPLER REMOVE/INSTALL - TJ480/530 ....................................................SECTION 21, CHAPTER 4 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-4-2 DRIVE COUPLER REMOVAL ................................................................................................................... 21-4-3 DRIVE COUPLER INSTALLATION ............................................................................................................ 21-4-6 16 SPEED POWERSHIFT TRANSMISSION REPAIR...................SECTION 21, CHAPTER 5 (Book 2 - 87525640) SPECIFICATIONS ...................................................................................................................................... 21-5-3 SPECIAL TORQUE VALUES ..................................................................................................................... 21-5-3 SPECIAL TOOLS ........................................................................................................................................ 21-5-4 TRANSMISSION DISASSEMBLY .............................................................................................................. 21-5-7 INPUT (FIRST) SHAFT DISASSEMBLY .................................................................................................. 21-5-18 PUMP (SECOND) SHAFT DISASSEMBLY .............................................................................................. 21-5-27 MASTER CLUTCH (FOURTH) SHAFT DISASSEMBLY .......................................................................... 21-5-33 OUTPUT (FIFTH) SHAFT DISASSEMBLY .............................................................................................. 21-5-41 COUNTER (THIRD) SHAFT DISASSEMBLY ........................................................................................... 21-5-48 CLEANING AND INSPECTION ................................................................................................................ 21-5-50 CLUTCH PACK CLEARANCE AND CLUTCH PACK TRAVEL TEST ..................................................... 21-5-52 1F, 1R, 2F AND 2R CLUTCH GEAR BEARING PRELOAD TEST .......................................................... 21-5-55 INPUT (FIRST) SHAFT ASSEMBLY ....................................................................................................... 21-5-58 PUMP (SECOND) SHAFT ASSEMBLY .................................................................................................... 21-5-72 MASTER CLUTCH (FOURTH) SHAFT ASSEMBLY ................................................................................ 21-5-82 OUTPUT (FIFTH) SHAFT ASSEMBLY .................................................................................................... 21-5-96 COUNTER (THIRD) SHAFT BEARING ASSEMBLY ............................................................................. 21-5-107 TRANSMISSION ASSEMBLY ................................................................................................................ 21-5-110 16 SPEED POWERSHIFT TRANSMISSION - HOW IT WORKS ..SECTION 21, CHAPTER 6 (Book 2 - 87525640) GENERAL DESCRIPTION OF OPERATION ........................................................................................... 21-6-3 Regulator Valve ......................................................................................................................................... 21-6-4 Lube Regulator Valve ................................................................................................................................ 21-6-5 Master Clutch Lube Valve ........................................................................................................................... 21-6-5 Range Selector Valve ............................................................................................................................... 21-6-6 MASTER CLUTCH CONTROL VALVE ..................................................................................................... 21-6-7 Transmission Power Flow ......................................................................................................................... 21-6-8 Default Settings ......................................................................................................................................... 21-6-8 Helical-cut Gears ....................................................................................................................................... 21-6-8 Shifting The Powershift Transmission ....................................................................................................... 21-6-9 REAR DRIVE LINE AND CARRIER BEARING..............................SECTION 21, CHAPTER 7 (Book 2 - 87525640) SPECIAL TORQUE VALUES ..................................................................................................................... 21-7-2 REAR DRIVE LINE AND CARRIER BEARING REMOVAL ..................................................................... 21-7-3 REAR DRIVE LINE AND CARRIER BEARING INSTALLATION ............................................................... 21-7-5 CHARGE PUMP REPAIR FOR 16-SPEED POWERSHIFT TRANSMISSION ...................................................SECTION 21, CHAPTER 8 (Book 2 - 87525640) SPECIFICATIONS ...................................................................................................................................... 21-8-3 SPECIAL TORQUE VALUES ..................................................................................................................... 21-8-3 PUMP DISASSEMBLY ............................................................................................................................... 21-8-4 PUMP ASSEMBLY ..................................................................................................................................... 21-8-7
  • 6. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 6 24 SPEED MANUAL TRANSMISSION REMOVAL AND INSTALLATION .....................................................................SECTION 21, CHAPTER 9 (Book 2 - 87525640) SPECIAL TOOLS ........................................................................................................................................ 21-9-3 SPECIAL TORQUE VALUES ..................................................................................................................... 21-9-3 24 SPEED TRANSMISSION REMOVAL .................................................................................................... 21-9-4 24 SPEED TRANSMISSION INSTALLATION .......................................................................................... 21-9-13 MASTER CLUTCH ADJUSTMENT .......................................................................................................... 21-9-23 SHIFT LEVER LINKAGE ADJUSTMENT ................................................................................................. 21-9-24 ENGINE/TRANSMISSION DRIVE COUPLER REMOVE/INSTALL - TJ380/430 ..................................................SECTION 21, CHAPTER 10 (Book 2 - 87525640) SPECIAL TORQUE VALUES ................................................................................................................... 21-10-2 DRIVE COUPLER REMOVAL ................................................................................................................. 21-10-3 DRIVE COUPLER INSTALLATION .......................................................................................................... 21-10-6 24 SPEED MANUAL TRANS HOW IT WORKS/ PRESSURE TESTING/REPAIR...................................................SECTION 21, CHAPTER 11 (Book 2 - 87525640) SPECIFICATIONS .................................................................................................................................... 21-11-4 SPECIAL TORQUE VALUES ................................................................................................................... 21-11-5 SPECIAL TOOLS ..................................................................................................................................... 21-11-6 PRESSURE TESTING SPECIFICATIONS ............................................................................................... 21-11-8 GENERAL SETUP PROCEDURE ............................................................................................................ 21-11-9 TRANSMISSION PRESSURE TEST PORT LOCATIONS ..................................................................... 21-11-11 TESTING THE LUBRICATION PRESSURE .......................................................................................... 21-11-13 TRANSMISSION SERIAL NUMBER IDENTIFICATION ......................................................................... 21-11-14 TRANSMISSION LUBRICATION CIRCUIT ............................................................................................ 21-11-15 TRANSMISSION OIL FLOW CHART ..................................................................................................... 21-11-16 DESCRIPTION OF OPERATION .......................................................................................................... 21-11-20 TRANSMISSION POWER FLOW ........................................................................................................... 21-11-24 STARTING IN A FORWARD SPEED ..................................................................................................... 21-11-26 STARTING IN A REVERSE SPEED ...................................................................................................... 21-11-27 TROUBLESHOOTING GUIDE ............................................................................................................... 21-11-35 NEUTRAL SAFETY SWITCH ADJUSTMENT ..................................................................................... 21-11-40 TRANSMISSION SPEED SENSOR ADJUSTMENT .............................................................................. 21-11-40 TRANSMISSION DISASSEMBLY .......................................................................................................... 21-11-41 SHIFT LEVER SEAL REPLACEMENT ................................................................................................. 21-11-53 INPUT SHAFT DISASSEMBLY .............................................................................................................. 21-11-54 INPUT SHAFT ASSEMBLY .................................................................................................................... 21-11-59 PUMP SHAFT DISASSEMBLY ............................................................................................................. 21-11-72 PUMP SHAFT ASSEMBLY .................................................................................................................... 21-11-75 SPEED SHAFT DISASSEMBLY ........................................................................................................... 21-11-81 SPEED SHAFT ASSEMBLY ................................................................................................................... 21-11-84 CENTER SHAFT DISASSEMBLY .......................................................................................................... 21-11-88 CENTER SHAFT ASSEMBLY ................................................................................................................ 21-11-90 RANGE SHAFT DISASSEMBLY ............................................................................................................ 21-11-94 RANGE SHAFT ASSEMBLY ................................................................................................................ 21-11-967 TRANSMISSION ASSEMBLY ............................................................................................................. 21-11-100 HIGH-LOW CLUTCH CONTROL ASSEMBLY ................................................................................... 21-11-118 HIGH-LOW CONTROL VALVE DISASSEMBLY .................................................................................. 21-11-119 REGULATOR VALVE ASSEMBLY ....................................................................................................... 21-11-121 REGULATOR VALVE DISASSEMBLY AND ASSEMBLY .................................................................... 21-11-122 MASTER CLUTCH CONTROL VALVE ASSEMBLY ............................................................................ 21-11-123 MASTER CLUTCH CONTROL VALVE DISASSEMBLY AND ASSEMBLY ......................................... 21-11-124 LOCKOUT VALVE ASSEMBLY ............................................................................................................ 21-11-126 LOCKOUT VALVE DISASSEMBLY AND ASSEMBLY ......................................................................... 21-11-127 MASTER CLUTCH CABLE ADJUSTMENT ......................................................................................... 21-11-128
  • 7. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 7 16-SPEED POWERSHIFT TRANSMISSION - PRESSURE TESTING AND TROUBLESHOOTING ................ SECTION 21, CHAPTER 12 (Book 2A - 87740916) RECOMMENDED TOOLS ....................................................................................................................... 21-12-3 SPECIAL TORQUE VALUES ................................................................................................................... 21-12-4 TRANSMISSION TROUBLESHOOTING ................................................................................................ 21-12-5 Important General Information ................................................................................................................ 21-12-5 Fault Code Retrieval ............................................................................................................................... 21-12-5 Fault Codes Recorded ............................................................................................................................ 21-12-6 No Fault Codes Recorded ....................................................................................................................... 21-12-7 Solenoid Swap Test ................................................................................................................................ 21-12-8 CLUTCH TEST PORT IDENTIFICATION ................................................................................................. 21-12-9 Transmission Clutch Pressure Test ...................................................................................................... 21-12-10 TEST PORT IDENTIFICATION .............................................................................................................. 21-12-15 PRESSURE TEST SPECIFICATIONS AND WORKSHEETS ................................................................ 21-12-16 LUBE TEST PORT IDENTIFICATION .................................................................................................... 21-12-19 LUBRICATION CIRCUIT PRESSURE TEST ....................................................................................... 21-12-20 MASTER CLUTCH LUBE TEST ............................................................................................................. 21-12-22 PTO CLUTCH PRESSURE TEST .......................................................................................................... 21-12-23 PTO AND TRANSMISSION PRESSURE TEST REASSEMBLY ........................................................... 21-12-25 16 SPEED POWERSHIFT TRANSMISSION, RANGE SELECTOR, PRESSURE REGULATOR AND MASTER CLUTCH VALVE REPAIR ......................................... SECTION 21, CHAPTER 13 (Book 2A - 87740916) SPECIAL TORQUE VALUES ................................................................................................................... 21-13-3 REGULATOR VALVE DISASSEMBLY ..................................................................................................... 21-13-4 CLEANING, INSPECTION AND SOLENOID VALVE TEST ................................................................... 21-13-12 REGULATOR VALVE ASSEMBLY ......................................................................................................... 21-13-15 RANGE SELECTOR VALVE DYNAMIC TEST ...................................................................................... 21-13-23 RANGE SELECTOR PWM VALVE TEST .............................................................................................. 21-13-26 RANGE SELECTOR VALVE DISASSEMBLY ........................................................................................ 21-13-29 RANGE SELECTOR VALVE ASSEMBLY .............................................................................................. 21-13-32 PTO SYSTEM HOW IT WORKS AND TROUBLESHOOTING ......SECTION 31, CHAPTER 1 (Book 3 - 87525644) POWER TAKE OFF, General Information .................................................................................................. 31-1-3 PTO LUBRICATION, General Information .................................................................................................. 31-1-4 PTO CONTROL PTO Control Switch ................................................................................................................................... 31-1-5 To Operate the PTO .................................................................................................................................. 31-1-5 To Stop the PTO ....................................................................................................................................... 31-1-5 PTO Electrical Circuit ................................................................................................................................ 31-1-6 PTO Switch in the OFF Position ............................................................................................................... 31-1-7 PTO Switch in the ON Position ................................................................................................................. 31-1-8 Diode Suppressed PTO Coil ..................................................................................................................... 31-1-9 Neutral Start Feature ................................................................................................................................. 31-1-9 PTO VALVE Operational Modes .................................................................................................................................. 31-1-10 PTO Control Valve Operation ................................................................................................................. 31-1-12 PTO Clutch Disengaged ......................................................................................................................... 31-1-13 PTO Modulated Engagement .................................................................................................................. 31-1-14 PTO Fully Engaged ................................................................................................................................. 31-1-15 PTO Clutch Drive .................................................................................................................................... 31-1-16 PTO Clutch .............................................................................................................................................. 31-1-17 PTO Brake .............................................................................................................................................. 31-1-18 PTO Drop Box and Clutch ....................................................................................................................... 31-1-19 Engine RPM Speed Circuit ..................................................................................................................... 31-1-19
  • 8. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 8 PTO SYSTEM TROUBLESHOOTING PTO Will Not Engage .............................................................................................................................. 31-1-20 PTO Will Not Disengage ......................................................................................................................... 31-1-21 PTO CLUTCH REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 31, CHAPTER 2 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-2-2 PTO CLUTCH ASSEMBLY REMOVAL ..................................................................................................... 31-2-3 PTO CLUTCH ASSEMBLY INSTALLATION ............................................................................................. 31-2-9 PTO DRIVE UNIT (CLUTCH) REPAIR ..........................................SECTION 31, CHAPTER 3 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-3-3 SPECIFICATIONS ...................................................................................................................................... 31-3-3 PTO DRIVE UNIT DISASSEMBLY ............................................................................................................ 31-3-4 PTO DRIVE UNIT ASSEMBLY (EXPLODED VIEW) ................................................................................ 31-3-13 PTO CLUTCH AND BRAKE ASSEMBLY (EXPLODED VIEW) ................................................................ 31-3-14 PTO DRIVE UNIT ASSEMBLY ................................................................................................................ 31-3-15 PTO CLUTCH REMOVAL AND INSTALLATION - TJ280/330.......SECTION 31, CHAPTER 4 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-4-2 PTO CLUTCH REMOVAL .......................................................................................................................... 31-4-3 PTO CLUTCH INSTALLATION .................................................................................................................. 31-4-5 PTO TRANSFER CASE REMOVAL AND INSTALLATION ...........SECTION 31, CHAPTER 5 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-5-2 SPECIAL TOOLS ........................................................................................................................................ 31-5-2 TRANSFER CASE REMOVAL .................................................................................................................. 31-5-3 TRANSFER CASE INSTALLATION ........................................................................................................ 31-5-10 PTO DROPBOX REPAIR...............................................................SECTION 31, CHAPTER 6 (Book 3 - 87525644) SPECIFICATIONS ...................................................................................................................................... 31-6-2 SPECIAL TORQUE VALUES ..................................................................................................................... 31-6-2 PTO DROPBOX DISASSEMBLY .............................................................................................................. 31-6-3 EXPLODED VIEW PTO DROPBOX ASSEMBLY ...................................................................................... 31-6-9 PTO DROPBOX ASSEMBLY ................................................................................................................... 31-6-10 PTO DRIVELINE HANGER BEARING..............................................SECTION 31, CHAPTER (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-7-2 PTO DRIVELINE HANGER BEARING REMOVAL .................................................................................... 31-7-3 HANGER BEARING ASSEMBLY REPAIR (Exploded View) ..................................................................... 31-7-5 HANGER BEARING DISASSEMBLY ......................................................................................................... 31-7-6 HANGER BEARING ASSEMBLY ............................................................................................................... 31-7-7 PTO DRIVELINE HANGER BEARING INSTALLATION .......................................................................... 31-7-10 PTO CLUTCH VALVE....................................................................SECTION 31, CHAPTER 8 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 31-8-2 PTO VALVE REMOVAL ............................................................................................................................. 31-8-3 PTO VALVE DISASSEMBLY ...................................................................................................................... 31-8-4 CLEANING AND INSPECTION .................................................................................................................. 31-8-7 PTO VALVE SOLENOID TESTS ............................................................................................................... 31-8-8 PTO VALVE SECTIONAL VIEW ................................................................................................................ 31-8-9 PTO VALVE ASSEMBLY .......................................................................................................................... 31-8-10 PTO VALVE INSTALLATION ................................................................................................................... 31-8-13
  • 9. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 9 POWER BRAKES SYSTEM - HOW IT WORKS AND TROUBLESHOOTING ..............................SECTION 33, CHAPTER 1 (Book 3 - 87525644) BRAKE SYSTEM ........................................................................................................................................ 33-1-3 General Information .................................................................................................................................. 33-1-3 General Description .................................................................................................................................. 33-1-4 Axle Pump ................................................................................................................................................. 33-1-4 Axle Cooling Filter ..................................................................................................................................... 33-1-5 Axle Lube Solenoid Valve ......................................................................................................................... 33-1-5 Pressure/Lube Control Valve .................................................................................................................... 33-1-6 Brake Lubrication and Jet Pump ............................................................................................................... 33-1-6 Pressure/Lube Control Valve .................................................................................................................... 33-1-7 Regulated Pressure Spool ...................................................................................................................... 33-1-8 Park Brake/Tow Valve ............................................................................................................................. 33-1-10 Park Brake Applied ................................................................................................................................ 33-1-11 Park Brake Released ............................................................................................................................ 33-1-11 Tow Valve .............................................................................................................................................. 33-1-11 BRAKE CIRCUIT COMPONENTS .......................................................................................................... 33-1-12 Brake Pedal ........................................................................................................................................... 33-1-12 Brake Control Valve .............................................................................................................................. 33-1-13 Brake Clutch Pack ................................................................................................................................. 33-1-13 Axle Brake Cylinders ............................................................................................................................. 33-1-13 HYDRAULIC BRAKE CONTROL ............................................................................................................ 33-1-14 General Description ............................................................................................................................... 33-1-14 Brake Valve ........................................................................................................................................... 33-1-14 Service Brake Circuit ............................................................................................................................. 33-1-15 Emergency Braking ............................................................................................................................... 33-1-18 BRAKE SYSTEM TROUBLESHOOTING................................................................................................... 33-1-19 SERVICE BRAKE VALVE..............................................................SECTION 33, CHAPTER 2 (Book 3 - 87525644) SPECIAL TORQUE VALUES ..................................................................................................................... 33-2-2 RECOMMENDED TOOLS .......................................................................................................................... 33-2-2 SERVICE BRAKE VALVE REMOVAL ....................................................................................................... 33-2-3 SERVICE BRAKE VALVE DISASSEMBLY ................................................................................................ 33-2-6 INSPECTION AND CLEANING .................................................................................................................. 33-2-8 BRAKE MAL-FUNCTION SWITCH TEST .................................................................................................. 33-2-8 SERVICE BRAKE VALVE EXPLODED VIEW ............................................................................................ 33-2-9 SERVICE BRAKE VALVE SECTIONAL VIEW ......................................................................................... 33-2-10 SERVICE BRAKE VALVE ASSEMBLY ................................................................................................... 33-2-11 SERVICE BRAKE VALVE INSTALLATION .............................................................................................. 33-2-13 2006 AND 2007 MODEL YEAR HYDRAULIC SCHEMATIC .....................................................POSTER 87522497 2008 MODEL YEAR HYDRAULIC SCHEMATIC .......................................................................POSTER 87722947 HOW TO READ SYMBOLS IN A HYDRAULIC SCHEMATIC ......SECTION 35, CHAPTER 1 (Book 4 - 87618159) Introduction ............................................................................................................................................... 35-1-3 Circuit Diagrams ........................................................................................................................................ 35-1-3 Symbol Systems ....................................................................................................................................... 35-1-3 Using Schematic Symbols ........................................................................................................................ 35-1-3 Reservoirs ............................................................................................................................................... 35-1-3 Lines, Tubes and Hoses .......................................................................................................................... 35-1-4 Crossing or Joining Lines ........................................................................................................................ 35-1-5 Pump Symbols ........................................................................................................................................ 35-1-5 Hydraulic Motor Symbols ........................................................................................................................ 35-1-6 Cylinder Symbols .................................................................................................................................... 35-1-6
  • 10. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 10 Pressure Control Symbols ........................................................................................................................ 35-1-7 Normally Closed ...................................................................................................................................... 35-1-7 Normally Open ........................................................................................................................................ 35-1-7 Relief Valve ............................................................................................................................................. 35-1-7 Pressure Reducing Valve ........................................................................................................................ 35-1-7 Sequence Valve ...................................................................................................................................... 35-1-8 Directional Control Symbols ...................................................................................................................... 35-1-8 Simplified Symbols .................................................................................................................................. 35-1-8 One Way Valve ....................................................................................................................................... 35-1-8 By Pass Valve ......................................................................................................................................... 35-1-8 Composite Symbols .................................................................................................................................. 35-1-8 One Way Valves ...................................................................................................................................... 35-1-8 Two Position Valves ................................................................................................................................ 35-1-8 Three Position Valves ............................................................................................................................. 35-1-9 Actuating Controls ................................................................................................................................... 35-1-9 Flow Control Symbols ............................................................................................................................... 35-1-9 Restrictors ............................................................................................................................................... 35-1-9 Accessories ............................................................................................................................................. 35-1-10 SIMPLE SCHEMATIC ............................................................................................................................... 35-1-12 COMMON SYMBOLS ............................................................................................................................... 35-1-14 Lines and Line Functions ........................................................................................................................ 35-1-14 Mechanical Devices ................................................................................................................................ 35-1-14 Pumps and Motors .................................................................................................................................. 35-1-14 Reservoirs ............................................................................................................................................... 35-1-15 Cylinders ................................................................................................................................................. 35-1-15 Valves ..................................................................................................................................................... 35-1-15 Valve Actuators ....................................................................................................................................... 35-1-17 Accessories................................................................................................................................................. 35-1-17 HYDRAULIC SYSTEM HOW IT WORKS WITH TROUBLESHOOTING .........................................................SECTION 35, CHAPTER 2 (Book 4 - 87618159) GENERAL INTRODUCTION ...................................................................................................................... 35-2-3 SPECIFICATIONS ...................................................................................................................................... 35-2-5 MODEL NUMBER LOCATION ................................................................................................................... 35-2-7 STANDARD AND HIGH FLOW PFC PISTON PUMPS .............................................................................. 35-2-8 Principle of Control .................................................................................................................................... 35-2-8 Engine Start Up ......................................................................................................................................... 35-2-8 Operating Modes ....................................................................................................................................... 35-2-8 Low Pressure Standby .............................................................................................................................. 35-2-8 Pressure and Flow Delivery and Compensation Principle ........................................................................ 35-2-8 Increased Flow Demand ........................................................................................................................... 35-2-9 Decreased Flow Demand .......................................................................................................................... 35-2-9 High Pressure Standby ............................................................................................................................. 35-2-9 Return to Low Pressure Standby .............................................................................................................. 35-2-9 Destroke Valve .......................................................................................................................................... 35-2-9 Model 480 and 530 Tractor Hydraulic Fan Pump And Motor .................................................................. 35-2-10 PRESSURE/FLOW COMPENSATED PUMP ........................................................................................... 35-2-12 PFC CHARGE PRESSURE TEST ........................................................................................................... 35-2-14 LOW PRESSURE AND HIGH PRESSURE STANDBY TESTS ............................................................... 35-2-16 PFC PISTON PUMP FLOW TEST AT REMOTE COUPLERS ................................................................. 35-2-17 MEGAFLOW PUMP LOW PRESSURE AND HIGH PRESSURE STANDBY TESTS .............................. 35-2-18 MEGAFLOW PFC PISTON PUMP FLOW TEST AT REMOTE COUPLERS ........................................... 35-2-20 REGULATED PRESSURE TEST ............................................................................................................. 35-2-21 REGULATED PRESSURE ADJUSTMENT PROCEDURE ...................................................................... 35-2-22 REGULATED/LUBE PUMP TESTS .......................................................................................................... 35-2-23
  • 11. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 11 480 and 530 HYDRAULIC FAN PUMP LOW PRESSURE STANDBY, HIGH PRESSURE AND FLOW TESTS .................................................................................................... 35-2-25 480 and 530 HYDRAULIC FAN MOTOR TEST ....................................................................................... 35-2-27 REGULATED PRESSURE / LUBE CONTROL SYSTEM ........................................................................ 35-2-28 REGULATOR VALVE ............................................................................................................................... 35-2-29 480 and 530 HYDRAULIC FAN CIRCUIT ................................................................................................ 35-2-30 480 and 530 HYDRAULIC FAN SYSTEM ................................................................................................ 35-2-31 STEERING PRIORITY VALVE ................................................................................................................. 35-2-32 HYDRAULIC FAN/MOTOR REMOVAL AND FAN MOTOR/PUMP REPAIR - TJ480/530....................................SECTION 35, CHAPTER 3 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 35-3-3 HYDRAULIC FAN AND FAN MOTOR REMOVAL ..................................................................................... 35-3-4 HYDRAULIC FAN AND FAN MOTOR INSTALLATION ........................................................................... 35-3-15 HYDRAULIC FAN PUMP REMOVAL ....................................................................................................... 35-3-28 HYDRAULIC FAN PUMP INSTALLATION ............................................................................................... 35-3-31 HYDRAULIC FAN MOTOR DISASSEMBLY ............................................................................................ 35-3-35 HYDRAULIC FAN MOTOR ASSEMBLY .................................................................................................. 35-3-39 COMPENSATOR CONTROL VALVE REMOVAL AND DISASSEMBLY ................................................. 35-3-42 COMPENSATOR CONTROL VALVE ASSEMBLY AND INSTALLATION ............................................... 35-3-43 HYDRAULIC FAN PUMP DISASSEMBLY ............................................................................................... 35-3-44 PUMP CLEANING AND INSPECTION ..................................................................................................... 35-3-51 PFC PISTON PUMP REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 35, CHAPTER 4 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 35-4-2 SPECIAL TOOLS ........................................................................................................................................ 35-4-2 PISTON PUMP REMOVAL ........................................................................................................................ 35-4-3 PISTON PUMP INSTALLATION ................................................................................................................ 35-4-8 START-UP PROCEDURE ........................................................................................................................ 35-4-13 GEAR PUMP REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 35, CHAPTER 5 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 35-5-2 SPECIAL TOOLS ........................................................................................................................................ 35-5-2 GEAR PUMP REMOVAL ........................................................................................................................... 35-5-3 GEAR PUMP INSTALLATION .................................................................................................................... 35-5-5 PFC AXIAL PISTON PUMP REPAIR.............................................SECTION 35, CHAPTER 6 (Book 4 - 87618159) SPECIFICATIONS ...................................................................................................................................... 35-6-3 SPECIAL TORQUE VALUES ..................................................................................................................... 35-6-4 PISTON PUMP DISASSEMBLY ................................................................................................................ 35-6-5 PRESSURE/FLOW COMPENSATOR DISASSEMBLY .......................................................................... 35-6-12 PISTON PUMP CLEANING AND INSPECTION .................................................................................... 35-6-16 PRESSURE/FLOW COMPENSATOR ASSEMBLY EXPLODED VIEW .................................................. 35-6-20 PRESSURE/FLOW COMPENSATOR ASSEMBLY ................................................................................ 35-6-21 PISTON PUMP ASSEMBLY EXPLODED VIEW ...................................................................................... 35-6-24 PISTON PUMP ASSEMBLY .................................................................................................................... 35-6-25
  • 12. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 12 HITCH SYSTEM - HOW IT WORKS..............................................SECTION 35, CHAPTER 7 (Book 4 - 87618159) THREE POINT HITCH ................................................................................................................................ 35-7-3 ELECTRONIC HITCH CONTROL .............................................................................................................. 35-7-4 Operator Controls and Settings ................................................................................................................. 35-7-5 ELECTRONIC HITCH CONTROL SYSTEM FEATURES .......................................................................... 35-7-7 HITCH CONTROL VALVE ........................................................................................................................ 35-7-14 General ................................................................................................................................................... 35-7-14 Raise and Lower Solenoids .................................................................................................................... 35-7-14 Raise and Lower Pilot Spools ................................................................................................................. 35-7-14 Raise Spool ............................................................................................................................................. 35-7-14 Lower Poppet .......................................................................................................................................... 35-7-14 Load Check Ball ...................................................................................................................................... 35-7-14 Manual Raise or Lower Control Pins ....................................................................................................... 35-7-14 Overload Relief Valve ............................................................................................................................. 35-7-14 Neutral Function and Troubleshooting .................................................................................................... 35-7-16 Raise Function and Troubleshooting ...................................................................................................... 35-7-18 Raise Function and Troubleshooting ...................................................................................................... 35-7-19 Lower Function and Troubleshooting ...................................................................................................... 35-7-20 Lower Function and Troubleshooting ...................................................................................................... 35-7-21 THREE POINT HITCH VALVE.......................................................SECTION 35, CHAPTER 8 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 35-8-2 TPH VALVE REMOVAL ............................................................................................................................. 35-8-3 TPH VALVE DISASSEMBLY ..................................................................................................................... 35-8-5 CLEANING AND INSPECTION ................................................................................................................ 35-8-9 HITCH VALVE SOLENOID TEST ............................................................................................................. 35-8-11 THREE POINT HITCH VALVE ................................................................................................................. 35-8-13 TPH VALVE ASSEMBLY .......................................................................................................................... 35-8-14 TPH VALVE INSTALLATION .................................................................................................................... 35-8-18 REMOTE ELECTRONIC HYD SYSTEMS - HOW IT WORKS/TROUBLESHOOTING.......................................SECTION 35, CHAPTER 9 (Book 4 - 87618159) REMOTE HYDRAULIC SYSTEM INTRODUCTION .................................................................................. 35-9-3 REMOTE SYSTEM CONTROLS (ELECTRONIC) ..................................................................................... 35-9-5 Remote Function Control .......................................................................................................................... 35-9-6 Full Function Position ................................................................................................................................ 35-9-6 Neutral Lock Position ................................................................................................................................ 35-9-6 Float Lock-Out Position ............................................................................................................................. 35-9-7 Non-Detent Raise Position ........................................................................................................................ 35-9-7 Hydraulic Motor Position ........................................................................................................................... 35-9-7 Hydraulic Valve Timer Control .................................................................................................................. 35-9-9 Variable Flow Control ................................................................................................................................ 35-9-9 Remote Valve Load Check Valves .......................................................................................................... 35-9-10 REMOTE VALVE PROPORTIONAL CURRENT CONTROL (PCC) SOLENOID OPERATION .............. 35-9-11 REMOTE VALVE OPERATION (ELECTRONIC) ..................................................................................... 35-9-12 REMOTE VALVE PROBLEMS AND WHERE TO LOOK ......................................................................... 35-9-20 ELECTRONIC REMOTE VALVE SYSTEM TESTING ............................................................................. 35-9-21 FAULT CODE RETRIEVAL ...................................................................................................................... 35-9-21 REGULATED PRESSURE CHECK .......................................................................................................... 35-9-24 REMOTE VALVE HIGH PRESSURE TEST ............................................................................................. 35-9-24 REMOTE VALVE PROPORTIONAL SOLENOID CHECK ....................................................................... 35-9-26 LOW PRESSURE AND HIGH PRESSURE STANDBY TESTS ............................................................... 35-9-27 REMOTE VALVE FLOW TEST ................................................................................................................ 35-9-29 REMOTE VALVE SIGNAL CHECK AND HITCH SIGNAL CHECK TEST ................................................ 35-9-31 REMOTE VALVE COUPLER TEST ......................................................................................................... 35-9-32 LOAD CHECK INSPECTION .................................................................................................................... 35-9-33
  • 13. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 13 HYDRAULIC GEAR (CHARGE) PUMP REPAIR .........................SECTION 35, CHAPTER 10 (Book 4 - 87618159) SPECIAL TORQUE VALUES ................................................................................................................... 35-10-2 PUMP DISASSEMBLY ............................................................................................................................. 35-10-3 CLEANING AND INSPECTION ................................................................................................................ 35-10-7 PUMP ASSEMBLY ................................................................................................................................... 35-10-8 HYDRAULIC FILTERS .................................................................SECTION 35, CHAPTER 11 (Book 4 - 87618159) SPECIFICATIONS .................................................................................................................................... 35-11-2 SERVICING THE HYDRAULIC AND TRANSMISSION OIL FILTERS ..................................................... 35-11-3 REMOTE AUXILIARY VALVE AND COUPLER, REMOVAL/INSTALLATION/REPAIR...........................................SECTION 35, CHAPTER 12 (Book 4 - 87618159) SPECIAL TORQUE VALUES ................................................................................................................... 35-12-3 REMOTE AUXILIARY VALVE MANIFOLD SEAL REPLACEMENT ........................................................ 35-12-4 REMOTE AUXILIARY VALVE SOLENOID TEST ................................................................................... 35-12-9 REMOTE AUXILIARY VALVE SOLENOID REMOVAL AND DISASSEMBLY ......................................... 35-12-9 REMOTE AUXILIARY VALVE SOLENOID ASSEMBLY AND INSTALLATION ..................................... 35-12-12 REMOTE AUXILIARY VALVE CONTROL SPOOL REMOVAL .............................................................. 35-12-15 REMOTE AUXILIARY VALVE CONTROL SPOOL INSTALLATION .................................................... 35-12-17 REMOTE AUXILIARY VALVE REMOVAL ............................................................................................. 35-12-19 REMOTE AUXILIARY VALVE SECTION DISASSEMBLY ..................................................................... 35-12-20 LOAD CHECK VALVE DISASSEMBLY ................................................................................................. 35-12-25 REMOTE AUXILIARY VALVE SECTION ASSEMBLY ........................................................................... 35-12-27 LOAD CHECK VALVE ASSEMBLY ....................................................................................................... 35-12-29 REMOTE AUXILIARY VALVE SECTION ASSEMBLY ........................................................................... 35-12-31 REMOTE AUXILIARY VALVE SECTION INSTALLATION ..................................................................... 35-12-36 HYDRAULIC GEAR PUMP AND PISTON PUMP REMOVE/INSTALL - TJ280/330 ..................................................SECTION 35, CHAPTER 13 (Book 4 - 87618159) SPECIAL TORQUE VALUES ................................................................................................................... 35-13-3 RECOMMENDED TOOLS ........................................................................................................................ 35-13-3 GEAR PUMP REMOVAL ......................................................................................................................... 35-13-4 GEAR PUMP INSTALLATION .................................................................................................................. 35-13-7 PFC PISTON PUMP REMOVAL .............................................................................................................. 35-13-9 PFC PISTON PUMP INSTALLATION ................................................................................................... 35-13-14 START-UP PROCEDURE ...................................................................................................................... 35-13-19 DRAWBAR REMOVAL AND INSTALLATION ...............................SECTION 37, CHAPTER 1 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 37-1-2 SPECIAL TOOLS ........................................................................................................................................ 37-1-2 DRAWBAR REMOVAL ............................................................................................................................... 37-1-3 DRAWBAR INSTALLATION ....................................................................................................................... 37-1-7 CENTER HINGE BEARINGS AND CONNECTING LINK - TJ380/430/480/530.........................................................................SECTION 39, CHAPTER 1 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 39-1-3 SPECIAL TOOL .......................................................................................................................................... 39-1-3 RECOMMENDED TOOLS .......................................................................................................................... 39-1-3 GENERAL INFORMATION ........................................................................................................................ 39-1-5 SEPARATING THE FRONT AND REAR FRAMES .................................................................................... 39-1-5 BOTTOM HINGE BEARING REPLACEMENT ....................................................................................... 39-1-11 CONNECTING LINK FRONT BUSHING REPLACEMENT ................................................................... 39-1-19 CONNECTING LINK REMOVAL .............................................................................................................. 39-1-21 CONNECTING LINK REAR BEARING REPLACEMENT ......................................................................... 39-1-22 CONNECTING LINK INSTALLATION ...................................................................................................... 39-1-23 CONNECTING THE FRONT AND REAR FRAMES .............................................................................. 39-1-25
  • 14. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 14 CENTER HINGE BEARINGS AND CONNECTING LINK - TJ280/330.......................................................................................SECTION 39, CHAPTER 2 (Book 4 - 87618159) SPECIAL TORQUE VALUES ..................................................................................................................... 39-2-3 SPECIAL TOOL .......................................................................................................................................... 39-2-3 RECOMMENDED TOOLS .......................................................................................................................... 39-2-3 GENERAL INFORMATION ........................................................................................................................ 39-2-5 SEPARATING THE FRONT AND REAR FRAMES .................................................................................... 39-2-5 BOTTOM HINGE BEARING REPLACEMENT ....................................................................................... 39-2-11 CONNECTING LINK FRONT BUSHING REPLACEMENT ................................................................... 39-2-19 CONNECTING LINK REMOVAL .............................................................................................................. 39-2-21 CONNECTING LINK REAR BEARING REPLACEMENT ......................................................................... 39-2-22 CONNECTING LINK INSTALLATION ...................................................................................................... 39-2-23 CONNECTING THE FRONT AND REAR FRAMES .............................................................................. 39-2-25 CENTER HINGE BEARINGS AND CONNECTING LINK, T9030, 9040, 9050, AND 9060 S/N Z7F204001 AND AFTER.... SECTION 39, CHAPTER 3 (Book 4A - 87740917) SPECIAL TORQUE VALUES ..................................................................................................................... 39-3-3 SPECIAL TOOL .......................................................................................................................................... 39-3-3 RECOMMENDED TOOLS .......................................................................................................................... 39-3-3 GENERAL INFORMATION ........................................................................................................................ 39-3-5 SEPARATING THE FRONT AND REAR FRAMES .................................................................................... 39-3-5 BOTTOM HINGE BEARING REPLACEMENT ....................................................................................... 39-3-12 CONNECTING LINK FRONT BUSHING REPLACEMENT ................................................................... 39-3-20 CONNECTING LINK REMOVAL .............................................................................................................. 39-3-22 CONNECTING LINK REAR BEARING REPLACEMENT ......................................................................... 39-3-23 CONNECTING LINK INSTALLATION ...................................................................................................... 39-3-24 CONNECTING THE FRONT AND REAR FRAMES .............................................................................. 39-3-26 STEERING COLUMN REPAIR ......................................................SECTION 41, CHAPTER 1 (Book 5 - 87525646) TILT STEERING COLUMN DISASSEMBLY ............................................................................................. 41-1-3 TILT STEERING COLUMN ASSEMBLY .................................................................................................... 41-1-5 CENTER CONSOLE, STEERING COLUMN, PEDALS AND SWITCHES.............................................................SECTION 41, CHAPTER 2 (Book 5 - 87525646) SPECIAL TOOLS ........................................................................................................................................ 41-2-3 SPECIAL TORQUE VALUES ..................................................................................................................... 41-2-3 STEERING WHEEL REMOVAL ................................................................................................................ 41-2-4 TRANSMISSION SHIFT LEVER REMOVAL .............................................................................................. 41-2-4 CENTER CONSOLE COVER REMOVAL .................................................................................................. 41-2-7 CENTER CONSOLE COVER INSTALLATION .......................................................................................... 41-2-9 TRANSMISSION SHIFT INSTALLATION ................................................................................................. 41-2-11 STEERING WHEEL INSTALLATION ....................................................................................................... 41-2-14 STEERING COLUMN REMOVAL ........................................................................................................... 41-2-15 STEERING COLUMN INSTALLATION .................................................................................................... 41-2-16 TILT STEERING COLUMN RELEASE CABLE REMOVAL ................................................................... 41-2-17 TILT STEERING COLUMN RELEASE CABLE INSTALLATION .............................................................. 41-2-18 CLUTCH AND BRAKE PEDAL ASSEMBLY REMOVAL ........................................................................ 41-2-20 CLUTCH AND BRAKE PEDAL ASSEMBLY INSTALLATION .................................................................. 41-2-22 DECELERATION SWITCH REMOVAL ................................................................................................... 41-2-25 DECELERATION SWITCH INSTALLATION ............................................................................................ 41-2-26 CLUTCH POTENTIOMETER REMOVAL ............................................................................................... 41-2-27 CLUTCH POTENTIOMETER INSTALLATION ......................................................................................... 41-2-28 CLUTCH POTENTIOMETER CALIBRATION .......................................................................................... 41-2-29 CLUTCH POTENTIOMETER CALIBRATION .......................................................................................... 41-2-31 DIFFERENTIAL LOCK BRAKE SWITCH REMOVAL ............................................................................ 41-2-34 DIFFERENTIAL LOCK BRAKE SWITCH INSTALLATION ....................................................................... 41-2-34
  • 15. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 15 HVAC PLENUM ACTUATOR MOTOR AND LOUVER REMOVAL ......................................................... 41-2-36 HVAC PLENUM ACTUATOR MOTOR AND LOUVER INSTALLATION .................................................. 41-2-39 TRANSMISSION SHIFT LEVER DISASSEMBLY .................................................................................. 41-2-42 TRANSMISSION SHIFT LEVER ASSEMBLY .......................................................................................... 41-2-49 STEERING HAND PUMP & PRIORITY/CONTROL VALVE REMOVE/INSTALL - TJ380/430/480/530 AND T9030/40/50/60 TRACTORS..........................................................SECTION 41, CHAPTER 3 (Book 5 - 87525646) SPECIAL TOOLS ........................................................................................................................................ 41-3-2 SPECIAL TORQUE VALUES ..................................................................................................................... 41-3-2 STEERING HAND PUMP REMOVAL ....................................................................................................... 41-3-3 STEERING TUBE LINES REMOVAL ......................................................................................................... 41-3-5 STEERING PRIORITY/CONTROL VALVE REMOVAL .............................................................................. 41-3-7 STEERING PRIORITY/CONTROL VALVE INSTALLATION ...................................................................... 41-3-8 STEERING TUBE LINES INSTALLATION ................................................................................................. 41-3-9 STEERING HAND PUMP INSTALLATION .............................................................................................. 41-3-11 STEERING HAND PUMP & PRIORITY/CONTROL VALVE REMOVE/INSTALL - TJ280/330 AND T9010/20 TRACTORS.......SECTION 41, CHAPTER 4 (Book 5 - 87525646) SPECIAL TOOLS ........................................................................................................................................ 41-4-2 SPECIAL TORQUE VALUES ..................................................................................................................... 41-4-2 STEERING HAND PUMP REMOVAL ....................................................................................................... 41-4-3 STEERING TUBE LINES REMOVAL ......................................................................................................... 41-4-5 STEERING PRIORITY/CONTROL VALVE REMOVAL .............................................................................. 41-4-7 STEERING PRIORITY/CONTROL VALVE INSTALLATION .................................................................... 41-4-10 STEERING TUBE LINES INSTALLATION ............................................................................................... 41-4-13 STEERING HAND PUMP INSTALLATION .............................................................................................. 41-4-15 STEERING SYSTEM HOW IT WORKS.........................................SECTION 41, CHAPTER 5 (Book 5 - 87525646) ELECTROHYDRAULIC STEERING SYSTEM (EHPS) .............................................................................. 41-5-3 PRIORITY / STEERING CONTROL VALVE (EHPS) ................................................................................. 41-5-4 EHPS STEERING SYSTEM ....................................................................................................................... 41-5-6 Engine Running Steering in Neutral Position ............................................................................................ 41-5-7 Engine Running, Turning Left ................................................................................................................... 41-5-9 EHPS Steering System ........................................................................................................................... 41-5-11 280 AND 330 MODELS STEERING LAYOUT ......................................................................................... 41-5-12 380, 430, 480 AND 530 MODELS STEERING LAYOUT ......................................................................... 41-5-13 FRONT AXLE REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 44, CHAPTER 1 (Book 5 - 87525646) SPECIAL TORQUE VALUES ..................................................................................................................... 44-1-3 SPECIAL TOOLS ........................................................................................................................................ 44-1-3 RECOMMENDED TOOLS .......................................................................................................................... 44-1-3 FRONT AXLE REMOVAL .......................................................................................................................... 44-1-4 FRONT AXLE INSTALLATION ................................................................................................................ 44-1-10 FRONT AXLE REMOVAL AND INSTALLATION - TJ280/330 .......SECTION 44, CHAPTER 2 (Book 5 - 87525646) SPECIAL TORQUE VALUES ....................................................................................................................... 44-2-3 SPECIAL TOOLS ........................................................................................................................................ 44-2-3 RECOMMENDED TOOLS .......................................................................................................................... 44-2-3 FRONT AXLE REMOVAL .......................................................................................................................... 44-2-4 FRONT AXLE INSTALLATION ................................................................................................................ 44-2-10
  • 16. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 16 REAR AXLE REMOVAL AND INSTALLATION - TJ380/430/480/530.........................................................................SECTION 44, CHAPTER 3 (Book 5 - 87525646) SPECIAL TORQUE VALUES ..................................................................................................................... 44-3-3 SPECIAL TOOLS ........................................................................................................................................ 44-3-3 RECOMMENDED TOOLS .......................................................................................................................... 44-3-3 REAR AXLE REMOVAL ............................................................................................................................ 44-3-4 REAR AXLE INSTALLATION .................................................................................................................. 44-3-13 REAR AXLE REMOVAL AND INSTALLATION - TJ280/330 .........SECTION 44, CHAPTER 4 (Book 5 - 87525646) SPECIAL TORQUE VALUES ..................................................................................................................... 44-4-3 SPECIAL TOOLS ........................................................................................................................................ 44-4-3 RECOMMENDED TOOLS .......................................................................................................................... 44-4-3 REAR AXLE REMOVAL ............................................................................................................................ 44-4-4 REAR AXLE INSTALLATION .................................................................................................................. 44-4-12 FRONT AND REAR AXLE REPAIR - 300 SERIES AXLES...........SECTION 44, CHAPTER 5 (Book 5 - 87525646) AXLE SPECIFICATIONS ............................................................................................................................ 44-5-4 SPECIAL TORQUE VALUES ..................................................................................................................... 44-5-4 SPECIAL TOOLS ........................................................................................................................................ 44-5-5 RECOMMENDED TOOLS .......................................................................................................................... 44-5-6 GENERAL INFORMATION ....................................................................................................................... 44-5-12 AXLE FINAL DRIVE REMOVAL ............................................................................................................... 44-5-12 FINAL DRIVE DISASSEMBLY ................................................................................................................. 44-5-14 PLANETARY CARRIER DISASSEMBLY ................................................................................................. 44-5-18 PLANETARY CARRIER ASSEMBLY ....................................................................................................... 44-5-19 FINAL DRIVE HOUSING ASSEMBLY ...................................................................................................... 44-5-21 FRONT COVER REMOVAL ..................................................................................................................... 44-5-26 FRONT COVER DISASSEMBLY ............................................................................................................. 44-5-28 FRONT COVER ASSEMBLY ................................................................................................................... 44-5-31 RH SIDE BRAKE CARRIER REMOVAL .................................................................................................. 44-5-37 BRAKE CARRIER/BEARING SUPPORT DISASSEMBLY ....................................................................... 44-5-38 RH BRAKE CARRIER ASSEMBLY PROCEDURES ................................................................................ 44-5-42 DIFFERENTIAL REMOVAL ...................................................................................................................... 44-5-47 DIFFERENTIAL CASE DISASSEMBLY PROCEDURES ......................................................................... 44-5-48 DIFFERENTIAL CASE ASSEMBLY PROCEDURES ............................................................................... 44-5-51 LH DIFFERENTIAL BEARING CARRIER DISASSEMBLY ...................................................................... 44-5-57 LH DIFFERENTIAL BEARING CARRIER ASSEMBLY ............................................................................ 44-5-58 ADJUSTING BEVEL PINION GEAR DEPTH ........................................................................................... 44-5-59 SETTING DIFFERENTIAL CARRIER BEARING PRELOAD ................................................................... 44-5-62 SETTING RING/PINION GEAR BACKLASH ............................................................................................ 44-5-65 RH BEARING CARRIER/BRAKE SUPPORT INSTALLATION ................................................................ 44-5-69 FRONT COVER INSTALLATION ............................................................................................................. 44-5-70 LEAK TESTING THE SERVICE BRAKE .................................................................................................. 44-5-73 LEAK TESTING THE PARK BRAKE ........................................................................................................ 44-5-74 LEAK TESTING THE DIFFERENTIAL LOCK ........................................................................................... 44-5-75 FINAL DRIVE INSTALLATION ................................................................................................................. 44-5-77 FRONT AND REAR AXLE REPAIR - 500 SERIES AXLES..........SECTION 44, CHAPTER 6 (Book 5 - 87525646) AXLE IDENTIFICATION ............................................................................................................................. 44-6-4 AXLE SPECIFICATIONS ............................................................................................................................ 44-6-5 SPECIAL TORQUE VALUES ..................................................................................................................... 44-6-5 SPECIAL TOOLS ....................................................................................................................................... 44-6-6 RECOMMENDED TOOLS .......................................................................................................................... 44-6-8 GENERAL INFORMATION ....................................................................................................................... 44-6-13 AXLE FINAL DRIVE REMOVAL ............................................................................................................... 44-6-13 FINAL DRIVE DISASSEMBLY ................................................................................................................ 44-6-15
  • 17. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 17 PLANETARY CARRIER DISASSEMBLY ................................................................................................ 44-6-19 PLANETARY CARRIER ASSEMBLY ....................................................................................................... 44-6-20 FINAL DRIVE HOUSING ASSEMBLY .................................................................................................... 44-6-22 PINION CARRIER REMOVAL .................................................................................................................. 44-6-28 PINION CARRIER DISASSEMBLY ......................................................................................................... 44-6-32 PINION CARRIER ASSEMBLY ................................................................................................................ 44-6-34 BRAKE CARRIER/BEARING SUPPORT REMOVAL ............................................................................ 44-6-39 BRAKE CARRIER/BEARING SUPPORT DISASSEMBLY ....................................................................... 44-6-40 RH BRAKE CARRIER ASSEMBLY PROCEDURES .............................................................................. 44-6-44 DIFFERENTIAL REMOVAL AND DISASSEMBLY ................................................................................. 44-6-49 DIFFERENTIAL CASE ASSEMBLY PROCEDURES ............................................................................. 44-6-53 LH DIFFERENTIAL BEARING SUPPORT DISASSEMBLY .................................................................. 44-6-59 LH DIFFERENTIAL BEARING SUPPORT ASSEMBLY ........................................................................... 44-6-60 ADJUSTING BEVEL PINION GEAR DEPTH ........................................................................................... 44-6-61 SETTING DIFFERENTIAL CARRIER BEARING PRELOAD ................................................................... 44-6-64 SETTING RING/PINION GEAR BACKLASH ............................................................................................ 44-6-67 CHECKING FOR CORRECT BEVEL PINION/GEAR TOOTH CONTACT ............................................ 44-6-68 BRAKE CARRIER/BEARING SUPPORT INSTALLATION ...................................................................... 44-6-70 PERFORMING THE BRAKE LEAK DOWN TEST ................................................................................... 44-6-73 DIFFERENTIAL LOCK LEAK TEST ......................................................................................................... 44-6-74 FINAL DRIVE INSTALLATION ................................................................................................................ 44-6-77 FRONT AND REAR AXLE REPAIR - 400 SERIES AXLES ...........SECTION 44, CHAPTER 7 (Book 5 - 87525646) AXLE IDENTIFICATION ............................................................................................................................. 44-7-4 AXLE SPECIFICATIONS ............................................................................................................................ 44-7-5 SPECIAL TORQUE VALUES ..................................................................................................................... 44-7-5 SPECIAL TOOLS ....................................................................................................................................... 44-7-6 RECOMMENDED TOOLS .......................................................................................................................... 44-7-7 GENERAL INFORMATION ....................................................................................................................... 44-7-13 AXLE FINAL DRIVE REMOVAL ............................................................................................................... 44-7-13 FINAL DRIVE DISASSEMBLY ................................................................................................................ 44-7-15 PLANETARY CARRIER DISASSEMBLY ................................................................................................. 44-7-19 PLANETARY CARRIER ASSEMBLY ....................................................................................................... 44-7-20 FINAL DRIVE HOUSING ASSEMBLY ...................................................................................................... 44-7-22 FRONT COVER REMOVAL ..................................................................................................................... 44-7-28 FRONT COVER DISASSEMBLY ............................................................................................................. 44-7-31 FRONT COVER ASSEMBLY ................................................................................................................... 44-7-33 RH SIDE BRAKE CARRIER REMOVAL .................................................................................................. 44-7-39 BRAKE CARRIER/BEARING SUPPORT DISASSEMBLY .................................................................... 44-7-40 RH BRAKE CARRIER ASSEMBLY PROCEDURES ................................................................................ 44-7-44 DIFFERENTIAL REMOVAL ..................................................................................................................... 44-7-49 DIFFERENTIAL CASE DISASSEMBLY PROCEDURES ......................................................................... 44-7-50 DIFFERENTIAL CASE ASSEMBLY PROCEDURES ............................................................................... 44-7-53 LH DIFFERENTIAL BEARING CARRIER DISASSEMBLY ................................................................... 44-7-59 LH DIFFERENTIAL BEARING CARRIER ASSEMBLY ............................................................................ 44-7-60 ADJUSTING BEVEL PINION GEAR DEPTH ........................................................................................... 44-7-61 SETTING DIFFERENTIAL CARRIER BEARING PRELOAD ................................................................... 44-7-64 SETTING RING/PINION GEAR BACKLASH ............................................................................................ 44-7-67 RH BEARING CARRIER/BRAKE SUPPORT INSTALLATION .............................................................. 44-7-71 FRONT COVER INSTALLATION ............................................................................................................. 44-7-72 LEAK TESTING THE SERVICE BRAKE .................................................................................................. 44-7-75 LEAK TESTING THE PARK BRAKE ........................................................................................................ 44-7-76 LEAK TESTING THE DIFFERENTIAL LOCK ........................................................................................... 44-7-77 FINAL DRIVE INSTALLATION ................................................................................................................. 44-7-79
  • 18. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 18 AXLE COOLING AND LUBRICATION SYSTEM ...........................SECTION 44, CHAPTER 8 (Book 5 - 87525646) AXLE LUBRICATION CIRCUIT .................................................................................................................. 44-8-3 TESTING THE AXLE LUBRICATION CIRCUIT ......................................................................................... 44-8-7 Visual Inspection ....................................................................................................................................... 44-8-7 Axle Lubrication Pressure Test ................................................................................................................. 44-8-7 Air Flow Test ............................................................................................................................................. 44-8-7 Axle Pressure Test .................................................................................................................................... 44-8-7 300 SERIES AXLE LUBRICATION CIRCUIT ............................................................................................. 44-8-8 300 SERIES AXLE LUBRICATION CIRCUIT ............................................................................................. 44-8-9 400 SERIES AXLE LUBRICATION CIRCUIT ........................................................................................... 44-8-10 400 SERIES AXLE LUBRICATION CIRCUIT ........................................................................................... 44-8-11 500 SERIES AXLE LUBRICATION CIRCUIT ........................................................................................... 44-8-12 500 SERIES AXLE LUBRICATION CIRCUIT ........................................................................................... 44-8-13 AIR CONDITIONER SYSTEM SERVICE.......................................SECTION 50, CHAPTER 1 (Book 6 - 87525647) SPECIFICATIONS ...................................................................................................................................... 50-1-4 SPECIAL TORQUES .................................................................................................................................. 50-1-4 SPECIAL TOOLS ........................................................................................................................................ 50-1-4 SAFETY PROCEDURES ............................................................................................................................ 50-1-8 AIR CONDITIONER SYSTEM REFRIGERANT RECOVERY .................................................................... 50-1-9 RECOVERING PURE 134A REFRIGERANT ........................................................................................... 50-1-11 RECOVERING CONTAMINATED REFRIGERANT WITH OEM1691 ...................................................... 50-1-15 Preparing the Tank .................................................................................................................................. 50-1-15 Recovery Process ................................................................................................................................... 50-1-17 AIR CONDITIONER SYSTEM EVACUATION AND RECHARGING ........................................................ 50-1-22 AIR CONDITIONING TEMPERATURE/PRESSURE CHART .................................................................. 50-1-27 LEAK DETECTION ................................................................................................................................... 50-1-28 Electronic Testing with OEM1437 ........................................................................................................... 50-1-29 Florescent Leak Detection ...................................................................................................................... 50-1-29 Fluorescent Dye Injection ...................................................................................................................... 50-1-30 Recovery Station Dye Injector Tool with a System in a Vacuum .......................................................... 50-1-30 Recovery Station Dye Injector Tool with a Charged System ................................................................. 50-1-31 Quick and Easy Dye Injector Tool with a Charged System ................................................................... 50-1-32 Compressor Oil Port .............................................................................................................................. 50-1-33 SP-20 PAG Oil Return Bottle ................................................................................................................ 50-1-34 Fluorescent Leak Testing ........................................................................................................................ 50-1-35 A/C SYSTEM FLUSHING PROCEDURE ................................................................................................. 50-1-36 Required Tools ........................................................................................................................................ 50-1-37 Precautions ............................................................................................................................................. 50-1-38 Component Flushing Procedure with Power Flush 17550 ...................................................................... 50-1-39 Complete Circuit Flushing Procedure with Power Flush 17550 .............................................................. 50-1-42 Back Flushing the Thermal Expansion Valve or Refrigerant Line ........................................................... 50-1-46 Post Flushing Procedures ....................................................................................................................... 50-1-48 Flushing Solvent Disposal ....................................................................................................................... 50-1-49 A/C SYSTEM COMPONENTS ................................................................................................................. 50-1-50 Cab HVAC Box Components - Automatic Temperature Control ............................................................. 50-1-50 TJ280/330 and T9010/20 Chassis Components ..................................................................................... 50-1-51 TJ380/430/480/530 and T9030/40/50/60 Chassis Components ............................................................. 50-1-53 A/C COMPRESSOR CLUTCH ................................................................................................................. 50-1-55 Clutch Removal ....................................................................................................................................... 50-1-55 Exploded View of Clutch ......................................................................................................................... 50-1-58 Compressor Clutch Replacement ........................................................................................................... 50-1-59
  • 19. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 19 A/C COMPRESSOR ................................................................................................................................. 50-1-63 Oil Level Check or Adjustment ................................................................................................................ 50-1-63 Injection Method .................................................................................................................................... 50-1-63 Dipstick Method ..................................................................................................................................... 50-1-64 Compressor Removal - TJ280/330 and T9010/20 .................................................................................. 50-1-66 Compressor Installation - TJ280/330 and T9010/20 ............................................................................... 50-1-68 Compressor Removal - TJ380/430/480/530 and T9030/40/50/60 .......................................................... 50-1-70 Compressor Installation - TJ380/430/480/530 and T9030/40/50/60 ....................................................... 50-1-71 Compressor Belt Installation and Adjustment - TJ280/330 and T9010/20 .............................................. 50-1-72 THERMAL EXPANSION VALVE TESTING .............................................................................................. 50-1-73 THERMAL EXPANSION VALVE REPLACEMENT .................................................................................. 50-1-74 CONDENSER AND RECEIVER-DRIER ................................................................................................... 50-1-75 ACCESSING THE HVAC BOX ................................................................................................................. 50-1-76 EVAPORATOR TEMPERATURE SENSOR LOCATION ......................................................................... 50-1-77 BLOWER MOTOR REPLACEMENT ........................................................................................................ 50-1-78 HEATER CONTROL VALVE REPLACEMENT ........................................................................................ 50-1-78 EVAPORATOR/HEATER ASSEMBLY ..................................................................................................... 50-1-79 Evaporator/Heater Assembly Removal ................................................................................................... 50-1-79 Evaporator/Heater Assembly Installation ................................................................................................ 50-1-82 Post Replacement Procedures ............................................................................................................... 50-1-84 EVAPORATOR/HEATER ASSEMBLY SEALING AND CLEANING ........................................................ 50-1-85 BLOWER AND EVAPORATOR REFERENCE ILLUSTRATION .............................................................. 50-1-86 ATC CONTROLLER, BLOWER DRIVER & STANDARD A/C CONTROLLER REPLACEMENT ............ 50-1-87 ACCESSING AND REPLACING THE MODE DOOR MOTOR ................................................................ 50-1-88 CAB INTAKE AIR FILTER SERVICE ....................................................................................................... 50-1-91 CAB RECIRCULATION AIR FILTER SERVICE ....................................................................................... 50-1-92 CAB PRESSURIZATION TEST ................................................................................................................ 50-1-93 CAB PRESSURIZER MOTOR REPLACEMENT ...................................................................................... 50-1-95 VISCOUS FAN DRIVE .............................................................................................................................. 50-1-95 AIR CONDITIONING SYSTEM -TROUBLESHOOTING................SECTION 50, CHAPTER 2 (Book 5 - 87525646) SAFETY PROCEDURES ............................................................................................................................ 50-2-4 SPECIAL TOOLS ........................................................................................................................................ 50-2-5 A/C THERMAL OPERATION ...................................................................................................................... 50-2-6 A/C SYSTEM COMPONENTS ................................................................................................................... 50-2-8 Cab HVAC Box Components - Automatic Temperature Control ............................................................... 50-2-8 TJ280/330 and T9010/20 Chassis Components ..................................................................................... 50-2-10 TJ380/430/480/530 and T9030/40/50/60 Chassis Components ............................................................. 50-2-12 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION ............................................................. 50-2-14 ATC FAULT CODES ................................................................................................................................. 50-2-21 ATC Fault Code 111 ............................................................................................................................... 50-2-21 ATC Fault Code 112 ............................................................................................................................... 50-2-22 ATC Fault Code 115 ............................................................................................................................... 50-2-22 ATC Fault Code 116 ............................................................................................................................... 50-2-23 ATC Fault Code 120 ............................................................................................................................... 50-2-23 ATC Fault Code 121 ............................................................................................................................... 50-2-24 ATC Fault Code 122 ............................................................................................................................... 50-2-24 ATC Fault Code 125 ............................................................................................................................... 50-2-25 ATC Fault Code 126 ............................................................................................................................... 50-2-25 ATC Fault Code 127 ............................................................................................................................... 50-2-26 ATC Fault Code 128 ............................................................................................................................... 50-2-26 ATC Fault Code 129 ............................................................................................................................... 50-2-27 ATC Fault Code 130 ............................................................................................................................... 50-2-27 ATC Fault Code 131 ............................................................................................................................... 50-2-28 ATC Fault Code 132 ............................................................................................................................... 50-2-28 ATC Fault Code 133 ............................................................................................................................... 50-2-29 ATC Fault Code 134 ............................................................................................................................... 50-2-30
  • 20. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 20 LOCATING SYSTEM PROBLEMS WITHOUT FAULT CODES ............................................................... 50-2-31 Controller-Based Resistance Tests ......................................................................................................... 50-2-31 ATC CONTROLLER TEST (CONNECTOR J8 TEST POINTS) ............................................................... 50-2-33 FIELD REPORTED SYMPTOMS/CAUSES ............................................................................................. 50-2-36 COMPRESSOR AND CLUTCH ................................................................................................................ 50-2-37 Operational Check .................................................................................................................................. 50-2-37 Electrical Test .......................................................................................................................................... 50-2-41 Compressor Clutch Control Circuit Test Procedure ................................................................................ 50-2-41 HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT ................................................. 50-2-44 Electrical Test .......................................................................................................................................... 50-2-46 High Pressure Switch and Circuit Test .................................................................................................... 50-2-46 Low Pressure Switch and Circuit Test .................................................................................................... 50-2-47 HEATER CONTROL VALVE .................................................................................................................... 50-2-48 Operational Check .................................................................................................................................. 50-2-48 Electrical Test .......................................................................................................................................... 50-2-49 Heater Control Valve Power, Signal and Ground Test ............................................................................ 50-2-49 BLOWER SPEED, TEMPERATURE CONTROL AND MODE DOOR POTS .......................................... 50-2-50 Electrical Test .......................................................................................................................................... 50-2-51 Common Control Potentiometer and Circuit Test Procedure .................................................................. 50-2-51 BLOWER AND BLOWER SPEED DRIVER ............................................................................................. 50-2-52 Blower Motor/Blower Driver Power, Signal and Ground Test ................................................................. 50-2-53 MODE DOOR CONTROL AND MOTOR .................................................................................................. 50-2-54 Electrical Test .......................................................................................................................................... 50-2-55 Mode Door Motor and Circuit Test .......................................................................................................... 50-2-55 CAB AND EVAPORATOR TEMPERATURE SENSORS ......................................................................... 50-2-56 Electrical Test .......................................................................................................................................... 50-2-57 Cab Temperature Sensor and Circuit Test ............................................................................................. 50-2-59 Evaporator Temperature Sensor and Circuit Test .................................................................................. 50-2-60 CONTROLLER POWER AND GROUND, ATC SWITCH ......................................................................... 50-2-62 Controller Power Supply and Ground Test ............................................................................................. 50-2-62 ATC Switch and Circuit Test ................................................................................................................... 50-2-63 Defog/Defrost Switch and Circuit Test .................................................................................................... 50-2-63 CAB PRESSURIZER BLOWER ............................................................................................................... 50-2-64 Cab Pressurizer Blower & Relay Power Supply and Ground Test .......................................................... 50-2-64 ACCESSING THE HVAC BOX ................................................................................................................. 50-2-65 2006 MODEL YEAR POWERSHIFT NAO ELECTRICAL SCHEMATIC ...................................POSTER 87517739 2007 MODEL YEAR POWERSHIFT NAO ELECTRICAL SCHEMATIC ...................................POSTER 87710064 2008 MODEL YEAR POWERSHIFT NAO ELECTRICAL SCHEMATIC ...................................POSTER 87708840
  • 21. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 21 AIR CONDITIONING SYSTEM -TROUBLESHOOTING, MODELS T9020, 9030, 9040, 9050 AND 9060 AFTER SERIAL NUMBER Z7F204001 ...................................... SECTION 50, CHAPTER 3 (Book 6A - 87740918) SAFETY PROCEDURES ............................................................................................................................ 50-3-4 SPECIAL TOOLS ........................................................................................................................................ 50-3-5 A/C THERMAL OPERATION ...................................................................................................................... 50-3-6 A/C SYSTEM COMPONENTS ................................................................................................................... 50-3-8 Cab HVAC Box Components - Automatic Temperature Control ............................................................... 50-3-8 T9020 Chassis Components ................................................................................................................... 50-3-10 T9030, 9040 and 9050 Chassis Components ......................................................................................... 50-3-12 T9060 Chassis Components ................................................................................................................... 50-3-13 AUTOMATIC TEMPERATURE CONTROL (ATC) OPERATION ............................................................. 50-3-15 ATC FAULT CODES ................................................................................................................................. 50-3-22 ATC Fault Code 111 ............................................................................................................................... 50-3-22 ATC Fault Code 112 ............................................................................................................................... 50-3-23 ATC Fault Code 115 ............................................................................................................................... 50-3-23 ATC Fault Code 116 ............................................................................................................................... 50-3-24 ATC Fault Code 120 ............................................................................................................................... 50-3-24 ATC Fault Code 121 ............................................................................................................................... 50-3-25 ATC Fault Code 122 ............................................................................................................................... 50-3-25 ATC Fault Code 125 ............................................................................................................................... 50-3-26 ATC Fault Code 126 ............................................................................................................................... 50-3-26 ATC Fault Code 127 ............................................................................................................................... 50-3-27 ATC Fault Code 128 ............................................................................................................................... 50-3-27 ATC Fault Code 129 ............................................................................................................................... 50-3-28 ATC Fault Code 130 ............................................................................................................................... 50-3-28 ATC Fault Code 131 ............................................................................................................................... 50-3-29 ATC Fault Code 132 ............................................................................................................................... 50-3-29 ATC Fault Code 133 ............................................................................................................................... 50-3-30 ATC Fault Code 134 ............................................................................................................................... 50-3-31 LOCATING SYSTEM PROBLEMS WITHOUT FAULT CODES ............................................................... 50-3-32 Controller-Based Resistance Tests ......................................................................................................... 50-3-32 ATC CONTROLLER TEST (CONNECTOR J8 TEST POINTS) ............................................................... 50-3-34 FIELD REPORTED SYMPTOMS/CAUSES ............................................................................................. 50-3-37 COMPRESSOR AND CLUTCH ................................................................................................................ 50-3-38 Operational Check .................................................................................................................................. 50-3-38 Electrical Test .......................................................................................................................................... 50-3-43 Compressor Clutch Control Circuit Test Procedure ................................................................................ 50-3-43 HIGH AND LOW PRESSURE SWITCH CLUTCH LATCHING CIRCUIT ................................................. 50-3-46 Electrical Test .......................................................................................................................................... 50-3-48 High Pressure Switch and Circuit Test .................................................................................................... 50-3-48 Low Pressure Switch and Circuit Test .................................................................................................... 50-3-49 HEATER CONTROL VALVE .................................................................................................................... 50-3-50 Operational Check .................................................................................................................................. 50-3-50 Electrical Test .......................................................................................................................................... 50-3-51 Heater Control Valve Power, Signal and Ground Test ............................................................................ 50-3-51 BLOWER SPEED, TEMPERATURE CONTROL AND MODE DOOR POTS ......................................... 50-3-52 Electrical Test .......................................................................................................................................... 50-3-53 Common Control Potentiometer and Circuit Test Procedure .................................................................. 50-3-53 BLOWER AND BLOWER SPEED DRIVER ............................................................................................. 50-3-54 Blower Motor/Blower Driver Power, Signal and Ground Test ................................................................. 50-3-55 MODE DOOR CONTROL AND MOTOR .................................................................................................. 50-3-56 Electrical Test .......................................................................................................................................... 50-3-57 Mode Door Motor and Circuit Test .......................................................................................................... 50-3-57 CAB AND EVAPORATOR TEMPERATURE SENSORS ......................................................................... 50-3-58 Electrical Test .......................................................................................................................................... 50-3-59 Cab Temperature Sensor and Circuit Test ............................................................................................. 50-3-61
  • 22. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 22 Evaporator Temperature Sensor and Circuit Test .................................................................................. 50-3-62 CONTROLLER POWER AND GROUND, ATC SWITCH ......................................................................... 50-3-64 Controller Power Supply and Ground Test ............................................................................................. 50-3-64 ATC Switch and Circuit Test ................................................................................................................... 50-3-65 Defog/Defrost Switch and Circuit Test .................................................................................................... 50-3-65 CAB PRESSURIZER BLOWER ............................................................................................................... 50-3-66 Cab Pressurizer Blower & Relay Power Supply and Ground Test .......................................................... 50-3-66 ACCESSING THE HVAC BOX ................................................................................................................. 50-3-67 ELECTRICAL SYSTEM - HOW IT WORKS AND TROUBLESHOOTING...........................................................SECTION 55, CHAPTER 1 (Book 7 - 87525648) SPECIAL TOOLS ........................................................................................................................................ 55-1-3 FUSE AND RELAY IDENTIFICATIONDELUXE CAB POWERSHIFT TRANSMISSION ........................... 55-1-4 FUSE AND RELAY IDENTIFICATIONDELUXE CAB 24 SPEED TRANSMISSION .................................. 55-1-6 INSTRUMENTATION AND CONTROLS .................................................................................................... 55-1-8 AUXILIARY AUTO MODE SWITCH (IF EQUIPPED) ............................................................................... 55-1-11 CONNECTOR AND COMPONENT LOCATION ...................................................................................... 55-1-13 ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS ............................................................... 55-1-89 AUDIO SYSTEM CIRCUIT OPERATION ................................................................................................. 55-1-90 CHARGING SYSTEM ............................................................................................................................... 55-1-95 POWER MIRROR SYSTEM ..................................................................................................................... 55-1-99 POWER SEAT SYSTEM ........................................................................................................................ 55-1-107 STARTING SYSTEM .............................................................................................................................. 55-1-112 WIPER / WASHER SYSTEM .................................................................................................................. 55-1-121 ELECTRONIC CONTROLLER CONFIG/CALIBRATION/ FAULT CODE RETRIVAL ..............................................................SECTION 55, CHAPTER 2 (Book 7 - 87525648) INSTRUMENTATION PROGRAMMING .................................................................................................... 55-2-3 Operation Setup ........................................................................................................................................ 55-2-3 Unit of Measure ......................................................................................................................................... 55-2-4 Tire Radius ................................................................................................................................................ 55-2-4 Radar Calibration ...................................................................................................................................... 55-2-7 Controller Configuration .......................................................................................................................... 55-2-10 ARMREST CONTROLLER CALIBRATION .............................................................................................. 55-2-15 Hitch Menu .............................................................................................................................................. 55-2-16 Throttle Menu .......................................................................................................................................... 55-2-18 Remote Valve Menu ................................................................................................................................ 55-2-18 TRANSMISSION CONTROLLER CALIBRATION .................................................................................... 55-2-23 Trans View Mode .................................................................................................................................... 55-2-25 Trans Setup Mode ................................................................................................................................... 55-2-33 Clutch Calibration Procedure .................................................................................................................. 55-2-35 Calibration Error Messages ..................................................................................................................... 55-2-40 Gear Default Mode .................................................................................................................................. 55-2-41 HITCH CONTROLLER CALIBRATION .................................................................................................... 55-2-43 Hitch Setting Menu .................................................................................................................................. 55-2-49 Hitch View Menu ..................................................................................................................................... 55-2-51 REMOTE HYDRAULICS CONTROLLER CALIBRATION ........................................................................ 55-2-52 Aux Setup Menu ...................................................................................................................................... 55-2-57 Aux Calibration Menu .............................................................................................................................. 55-2-58 Aux 67 Mode Lever Menu ....................................................................................................................... 55-2-72 FAULT CODE RETRIEVAL ...................................................................................................................... 55-2-74
  • 23. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 23 ELECTRONIC CONTROLLER CONFIGURATION, CALIBRATION AND FAULT CODE RETRIEVAL FOR T9020, 9030, 9040, 9050, AND 9060 SERIES TRACTORS, S/N Z7F204001 and After....SECTION 55, CHAPTER 2A (Book 7A - 87740919) INSTRUMENTATION PROGRAMMING .................................................................................................. 55-2A-3 Operation Setup ...................................................................................................................................... 55-2A-3 Unit of Measure ....................................................................................................................................... 55-2A-4 Tire Radius .............................................................................................................................................. 55-2A-4 Radar Calibration .................................................................................................................................... 55-2A-7 Controller Configuration ........................................................................................................................ 55-2A-10 ARMREST CONTROLLER CALIBRATION ............................................................................................ 55-2A-15 Hitch Menu ............................................................................................................................................ 55-2A-16 Throttle Menu ........................................................................................................................................ 55-2A-19 Remote Valve Menu .............................................................................................................................. 55-2A-19 Exit Calibration ...................................................................................................................................... 55-2A-25 TRANSMISSION CONTROLLER CALIBRATION .................................................................................. 55-2A-26 Trans View Mode .................................................................................................................................. 55-2A-28 Trans Setup Mode ................................................................................................................................. 55-2A-36 Clutch Calibration Procedure ................................................................................................................ 55-2A-39 Calibration Error Messages ................................................................................................................... 55-2A-44 Gear Default Mode ................................................................................................................................ 55-2A-45 HITCH CONTROLLER CALIBRATION .................................................................................................. 55-2A-47 Hitch Setting Menu ................................................................................................................................ 55-2A-53 Hitch View Menu ................................................................................................................................... 55-2A-55 REMOTE HYDRAULICS CONTROLLER CALIBRATION ...................................................................... 55-2A-56 Aux Setup Menu .................................................................................................................................... 55-2A-61 Aux Calibration Menu ............................................................................................................................ 55-2A-62 Aux 67 Mode Lever Menu ..................................................................................................................... 55-2A-76 FAULT CODE RETRIEVAL .................................................................................................................... 55-2A-78 HITCH CONTROLLER FAULT CODES.........................................SECTION 55, CHAPTER 3 (Book 7 - 87525648) FAULT CODE HITCH 1020 ........................................................................................................................ 55-3-5 FAULT CODE HITCH 1030 ........................................................................................................................ 55-3-6 FAULT CODE HITCH 3010 ........................................................................................................................ 55-3-7 FAULT CODE HITCH 3020 ........................................................................................................................ 55-3-9 FAULT CODE HITCH 3030 ...................................................................................................................... 55-3-10 FAULT CODE HITCH 4019 ...................................................................................................................... 55-3-11 FAULT CODE HITCH 4029 ...................................................................................................................... 55-3-12 FAULT CODE HITCH 4039 ...................................................................................................................... 55-3-13 FAULT CODE HITCH 4049 ...................................................................................................................... 55-3-14 FAULT CODE HITCH 6014 ...................................................................................................................... 55-3-15 FAULT CODE HITCH 6015 ...................................................................................................................... 55-3-16 FAULT CODE HITCH 6024 ...................................................................................................................... 55-3-17 FAULT CODE HITCH 6025 ...................................................................................................................... 55-3-18 FAULT CODE HITCH 8001 ...................................................................................................................... 55-3-19 FAULT CODE HITCH 8002 ...................................................................................................................... 55-3-20 FAULT CODE HITCH 9301 ...................................................................................................................... 55-3-21 FAULT CODE HITCH 9302 ...................................................................................................................... 55-3-22 FAULT CODE HITCH 9303 ...................................................................................................................... 55-3-23 FAULT CODE HITCH 9304 ...................................................................................................................... 55-3-24 FAULT CODE HITCH 9306 ...................................................................................................................... 55-3-25 FAULT CODE HITCH 9307 ...................................................................................................................... 55-3-26 FAULT CODE HITCH 9308 ...................................................................................................................... 55-3-27 FAULT CODE HITCH 9309 ...................................................................................................................... 55-3-28 FAULT CODE HITCH 9310 ...................................................................................................................... 55-3-29 FAULT CODE HITCH 9311 ...................................................................................................................... 55-3-30 FAULT CODE HITCH 9312 ...................................................................................................................... 55-3-31 FAULT CODE HITCH 9313 ...................................................................................................................... 55-3-32
  • 24. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 24 FAULT CODE HITCH 9314 ...................................................................................................................... 55-3-33 FAULT CODE HITCH 9315 ...................................................................................................................... 55-3-34 FAULT CODE HITCH 9316 ...................................................................................................................... 55-3-35 FAULT CODE HITCH 9317 ...................................................................................................................... 55-3-36 FAULT CODE HITCH 9318 ...................................................................................................................... 55-3-37 FAULT CODE HITCH 9319 ...................................................................................................................... 55-3-38 FAULT CODE HITCH 9320 ...................................................................................................................... 55-3-39 FAULT CODE HITCH 9321 ...................................................................................................................... 55-3-40 FAULT CODE HITCH 10030 .................................................................................................................... 55-3-41 FAULT CODE HITCH 10060 .................................................................................................................... 55-3-42 FAULT CODE HITCH 10061 .................................................................................................................... 55-3-43 FAULT CODE HITCH 10071 .................................................................................................................... 55-3-44 FAULT CODE HITCH 10072 .................................................................................................................... 55-3-45 FAULT CODE HITCH 10090 .................................................................................................................... 55-3-46 FAULT CODE HITCH 11010 .................................................................................................................... 55-3-47 FAULT CODE HITCH 11020 .................................................................................................................... 55-3-48 FAULT CODE HITCH 11030 .................................................................................................................... 55-3-49 FAULT CODE HITCH 11050 .................................................................................................................... 55-3-50 FAULT CODE HITCH 11069 .................................................................................................................... 55-3-51 FAULT CODE HITCH 11070 .................................................................................................................... 55-3-52 FAULT CODE HITCH 12011 .................................................................................................................... 55-3-53 FAULT CODE HITCH 12031 .................................................................................................................... 55-3-56 FAULT CODE HITCH 12041 .................................................................................................................... 55-3-58 FAULT CODE HITCH 52230 .................................................................................................................... 55-3-61 FAULT CODE HITCH 52260 .................................................................................................................... 55-3-62 FAULT CODE HITCH 65535 ..................................................................................................................... 55-3-63 TRANSMISSION CONTROLLER FAULT CODES ........................SECTION 55, CHAPTER 4 (Book 7 - 87525648) (TJ 280, 330, 380, 430, 480, and 530 Series and T9010, 20, 30, 40, 50, and 9060 Series Before S/N Z7F204001) FAULT CODE TRANS 11 ........................................................................................................................... 55-4-4 FAULT CODE TRANS 12 ........................................................................................................................... 55-4-5 FAULT CODE TRANS 24 ........................................................................................................................... 55-4-6 FAULT CODE TRANS 37 ........................................................................................................................... 55-4-7 FAULT CODE TRANS 38 ........................................................................................................................... 55-4-8 FAULT CODE TRANS 47 ........................................................................................................................... 55-4-9 FAULT CODE TRANS 48 ......................................................................................................................... 55-4-11 FAULT CODE TRANS 50 ......................................................................................................................... 55-4-12 FAULT CODE TRANS 51 ......................................................................................................................... 55-4-13 FAULT CODE TRANS 52 ......................................................................................................................... 55-4-14 FAULT CODE TRANS 53 ......................................................................................................................... 55-4-15 FAULT CODE TRANS 54 ......................................................................................................................... 55-4-17 FAULT CODE TRANS 59 ......................................................................................................................... 55-4-19 FAULT CODE TRANS 60 ......................................................................................................................... 55-4-20 FAULT CODE TRANS 66 ......................................................................................................................... 55-4-22 FAULT CODE TRANS 67 ......................................................................................................................... 55-4-23 FAULT CODE TRANS 68 ......................................................................................................................... 55-4-24 FAULT CODE TRANS 69 ......................................................................................................................... 55-4-25 FAULT CODE TRANS 70 ......................................................................................................................... 55-4-26 FAULT CODE TRANS 77 ......................................................................................................................... 55-4-27 FAULT CODE TRANS 80 ......................................................................................................................... 55-4-28 FAULT CODE TRANS 81 ......................................................................................................................... 55-4-30 FAULT CODE TRANS 83 ......................................................................................................................... 55-4-32 FAULT CODE TRANS 103 ....................................................................................................................... 55-4-33 FAULT CODE TRANS 104 ....................................................................................................................... 55-4-34 FAULT CODE TRANS 105 ....................................................................................................................... 55-4-35 FAULT CODE TRANS 106 ....................................................................................................................... 55-4-36 FAULT CODE TRANS 107 ....................................................................................................................... 55-4-37
  • 25. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 25 FAULT CODE TRANS 108 ....................................................................................................................... 55-4-38 FAULT CODE TRANS 109 ....................................................................................................................... 55-4-39 FAULT CODE TRANS 110 ....................................................................................................................... 55-4-40 FAULT CODE TRANS 112 ....................................................................................................................... 55-4-41 FAULT CODE TRANS 113 ....................................................................................................................... 55-4-42 FAULT CODE TRANS 114 ....................................................................................................................... 55-4-43 FAULT CODE TRANS 115 ....................................................................................................................... 55-4-44 FAULT CODE TRANS 116 ....................................................................................................................... 55-4-45 FAULT CODE TRANS 117 ....................................................................................................................... 55-4-46 FAULT CODE TRANS 118 ....................................................................................................................... 55-4-47 FAULT CODE TRANS 119 ....................................................................................................................... 55-4-48 FAULT CODE TRANS 120 ....................................................................................................................... 55-4-49 FAULT CODE TRANS 122 ....................................................................................................................... 55-4-50 FAULT CODE TRANS 123 ....................................................................................................................... 55-4-51 FAULT CODE TRANS 125 ....................................................................................................................... 55-4-52 FAULT CODE TRANS 126 ....................................................................................................................... 55-4-53 FAULT CODE TRANS 127 ....................................................................................................................... 55-4-54 FAULT CODE TRANS 128 ....................................................................................................................... 55-4-55 FAULT CODE TRANS 129 ....................................................................................................................... 55-4-56 FAULT CODE TRANS 130 ....................................................................................................................... 55-4-57 FAULT CODE TRANS 131 ....................................................................................................................... 55-4-58 FAULT CODE TRANS 132 ....................................................................................................................... 55-4-59 FAULT CODE TRANS 133 ....................................................................................................................... 55-4-60 FAULT CODE TRANS 135 ....................................................................................................................... 55-4-61 FAULT CODE TRANS 136 ....................................................................................................................... 55-4-63 FAULT CODE TRANS 146 ....................................................................................................................... 55-4-65 FAULT CODE TRANS 147 ....................................................................................................................... 55-4-66 FAULT CODE TRANS 148 ....................................................................................................................... 55-4-68 ARMREST CONTROLLER FAULT CODES ..................................SECTION 55, CHAPTER 5 (Book 7 - 87525648) (TJ 280, 330, 380, 430, 480, and 530 Series and T9010, 20, 30, 40, 50, and 9060 Series Before S/N Z7F204001) FAULT CODE ARM 19 ............................................................................................................................... 55-5-4 FAULT CODE ARM 29 ............................................................................................................................... 55-5-5 FAULT CODE ARM 39 ............................................................................................................................... 55-5-6 FAULT CODE ARM 49 ............................................................................................................................... 55-5-7 FAULT CODE ARM 59 ............................................................................................................................... 55-5-8 FAULT CODE ARM 69 ............................................................................................................................... 55-5-9 FAULT CODE ARM 79 ............................................................................................................................. 55-5-10 FAULT CODE ARM 89 ............................................................................................................................. 55-5-11 FAULT CODE ARM 99 ............................................................................................................................. 55-5-12 FAULT CODE ARM 109 ........................................................................................................................... 55-5-13 FAULT CODE ARM 119 ........................................................................................................................... 55-5-14 FAULT CODE ARM 129 ........................................................................................................................... 55-5-15 FAULT CODE ARM 139 ........................................................................................................................... 55-5-16 FAULT CODE ARM 149 ........................................................................................................................... 55-5-17 FAULT CODE ARM 159 ........................................................................................................................... 55-5-18 FAULT CODE ARM 169 ........................................................................................................................... 55-5-19 FAULT CODE ARM 1019 ......................................................................................................................... 55-5-20 FAULT CODE ARM 1029 ......................................................................................................................... 55-5-21 FAULT CODE ARM 1039 ......................................................................................................................... 55-5-22 FAULT CODE ARM 1049 ......................................................................................................................... 55-5-23 FAULT CODE ARM 1059 ......................................................................................................................... 55-5-24 FAULT CODE ARM 1069 ......................................................................................................................... 55-5-25 FAULT CODE ARM 1079 ......................................................................................................................... 55-5-26 FAULT CODE ARM 1109 ......................................................................................................................... 55-5-27 FAULT CODE ARM 1119 ......................................................................................................................... 55-5-28 FAULT CODE ARM 1129 ......................................................................................................................... 55-5-29
  • 26. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 26 FAULT CODE ARM 1139 ......................................................................................................................... 55-5-30 FAULT CODE ARM 8011 ......................................................................................................................... 55-5-31 FAULT CODE ARM 9011 ......................................................................................................................... 55-5-32 FAULT CODE ARM 9012 ......................................................................................................................... 55-5-33 FAULT CODE ARM 9013 ......................................................................................................................... 55-5-34 FAULT CODE ARM 9014 ......................................................................................................................... 55-5-35 FAULT CODE ARM 9015 ......................................................................................................................... 55-5-36 FAULT CODE ARM 9021 ......................................................................................................................... 55-5-37 FAULT CODE ARM 9031 ......................................................................................................................... 55-5-38 FAULT CODE ARM 10091 ....................................................................................................................... 55-5-39 FAULT CODE ARM 12013 ....................................................................................................................... 55-5-40 FAULT CODE ARM 12081 ....................................................................................................................... 55-5-42 FAULT CODE ARM 65535 ....................................................................................................................... 55-5-44 REMOTE HYDRAULICS CONTROLLER FAULT CODES ............SECTION 55, CHAPTER 6 (Book 8 - 87525649) FAULT CODE AUX - 1030 .......................................................................................................................... 55-6-5 FAULT CODE AUX 1040 ............................................................................................................................ 55-6-6 FAULT CODE AUX 1050 ............................................................................................................................ 55-6-7 FAULT CODE AUX 1060 ............................................................................................................................ 55-6-8 FAULT CODE AUX 1090 ............................................................................................................................ 55-6-9 FAULT CODE AUX 1100 .......................................................................................................................... 55-6-10 FAULT CODE AUX 8011 .......................................................................................................................... 55-6-11 FAULT CODE AUX 8012 .......................................................................................................................... 55-6-12 FAULT CODE AUX 9009 .......................................................................................................................... 55-6-13 FAULT CODE AUX 9019 .......................................................................................................................... 55-6-14 FAULT CODE AUX 9029 .......................................................................................................................... 55-6-15 FAULT CODE AUX 11010 ........................................................................................................................ 55-6-16 FAULT CODE AUX 11020 ........................................................................................................................ 55-6-17 FAULT CODE AUX 11030 ........................................................................................................................ 55-6-18 FAULT CODE AUX 11040 ........................................................................................................................ 55-6-19 FAULT CODE AUX 11060 ........................................................................................................................ 55-6-20 FAULT CODE AUX 11070 ........................................................................................................................ 55-6-21 FAULT CODE AUX 11080 ........................................................................................................................ 55-6-22 FAULT CODE AUX 11090 ........................................................................................................................ 55-6-23 FAULT CODE AUX 11100 ........................................................................................................................ 55-6-24 FAULT CODE AUX 11110 ........................................................................................................................ 55-6-25 FAULT CODE AUX 12011 ........................................................................................................................ 55-6-26 FAULT CODE AUX 12041 ........................................................................................................................ 55-6-29 FAULT CODE AUX 51011 ........................................................................................................................ 55-6-32 FAULT CODE AUX 51012 ........................................................................................................................ 55-6-33 FAULT CODE AUX 51029 ........................................................................................................................ 55-6-34 FAULT CODE AUX 51031 ........................................................................................................................ 55-6-35 FAULT CODE AUX 51032 ........................................................................................................................ 55-6-36 FAULT CODE AUX 51039 ........................................................................................................................ 55-6-37 FAULT CODE AUX 51041 ........................................................................................................................ 55-6-38 FAULT CODE AUX 51042 ........................................................................................................................ 55-6-39 FAULT CODE AUX 51049 ........................................................................................................................ 55-6-40 FAULT CODE AUX 51053 ........................................................................................................................ 55-6-41 FAULT CODE AUX 51054 ........................................................................................................................ 55-6-42 FAULT CODE AUX 51055 ........................................................................................................................ 55-6-43 FAULT CODE AUX 51056 ........................................................................................................................ 55-6-45 FAULT CODE AUX 51063 ........................................................................................................................ 55-6-47 FAULT CODE AUX 51064 ........................................................................................................................ 55-6-48 FAULT CODE AUX 51065 ........................................................................................................................ 55-6-49
  • 27. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 27 FAULT CODE AUX 51066 ........................................................................................................................ 55-6-51 FAULT CODE AUX 51073 ........................................................................................................................ 55-6-53 FAULT CODE AUX 51074 ........................................................................................................................ 55-6-54 FAULT CODE AUX 51075 ........................................................................................................................ 55-6-55 FAULT CODE AUX 51076 ........................................................................................................................ 55-6-57 FAULT CODE AUX 51083 ........................................................................................................................ 55-6-59 FAULT CODE AUX 51084 ........................................................................................................................ 55-6-60 FAULT CODE AUX 51085 ........................................................................................................................ 55-6-61 FAULT CODE AUX 51086 ........................................................................................................................ 55-6-63 FAULT CODE AUX 51093 ........................................................................................................................ 55-6-65 FAULT CODE AUX 51094 ........................................................................................................................ 55-6-66 FAULT CODE AUX 51095 ........................................................................................................................ 55-6-67 FAULT CODE AUX 51096 ........................................................................................................................ 55-6-69 FAULT CODE AUX 51101 ........................................................................................................................ 55-6-71 FAULT CODE AUX 51103 ........................................................................................................................ 55-6-72 FAULT CODE AUX 51105 ........................................................................................................................ 55-6-73 FAULT CODE AUX 51107 ........................................................................................................................ 55-6-74 FAULT CODE AUX 51109 ........................................................................................................................ 55-6-75 FAULT CODE AUX 51112 ........................................................................................................................ 55-6-76 FAULT CODE AUX 51114 ........................................................................................................................ 55-6-77 FAULT CODE AUX 51116 ........................................................................................................................ 55-6-78 FAULT CODE AUX 51118 ........................................................................................................................ 55-6-79 FAULT CODE AUX 51121 ........................................................................................................................ 55-6-80 FAULT CODE AUX 51123 ........................................................................................................................ 55-6-81 FAULT CODE AUX 51125 ........................................................................................................................ 55-6-82 FAULT CODE AUX 51127 ........................................................................................................................ 55-6-83 FAULT CODE AUX 51129 ........................................................................................................................ 55-6-84 FAULT CODE AUX 51132 ........................................................................................................................ 55-6-85 FAULT CODE AUX 51134 ........................................................................................................................ 55-6-86 FAULT CODE AUX 51136 ........................................................................................................................ 55-6-87 FAULT CODE AUX 51138 ........................................................................................................................ 55-6-88 FAULT CODE AUX 51141 ........................................................................................................................ 55-6-89 FAULT CODE AUX 51143 ........................................................................................................................ 55-6-90 FAULT CODE AUX 51145 ........................................................................................................................ 55-6-91 FAULT CODE AUX 51147 ........................................................................................................................ 55-6-92 FAULT CODE AUX 51149 ........................................................................................................................ 55-6-93 FAULT CODE AUX 51250 ........................................................................................................................ 55-6-94 FAULT CODE AUX 51261 ........................................................................................................................ 55-6-95 FAULT CODE AUX 51262 ........................................................................................................................ 55-6-96 FAULT CODE AUX 51401 ........................................................................................................................ 55-6-97 FAULT CODE AUX 51402 ........................................................................................................................ 55-6-98 FAULT CODE AUX 51411 ........................................................................................................................ 55-6-99 FAULT CODE AUX 51412 ...................................................................................................................... 55-6-100 FAULT CODE AUX 65535 ...................................................................................................................... 55-6-101
  • 28. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 28 INSTRUMENTATION CONTROLLER FAULT CODES .................SECTION 55, CHAPTER 7 (Book 8 - 87525649) (TJ 280, 330, 380, 430, 480, and 530 Series and T9010, 20, 30, 40, 50, and 9060 Series Before S/N Z7F204001) FAULT CODE INST 1015 ........................................................................................................................... 55-7-4 FAULT CODE INST 3010 ........................................................................................................................... 55-7-5 FAULT CODE INST 3020 ........................................................................................................................... 55-7-6 FAULT CODE INST 3022 ........................................................................................................................... 55-7-7 FAULT CODE INST 5010 ........................................................................................................................... 55-7-7 FAULT CODE INST 5011 ........................................................................................................................... 55-7-7 FAULT CODE INST 10031 ......................................................................................................................... 55-7-8 FAULT CODE INST 10032 ......................................................................................................................... 55-7-9 FAULT CODE INST 10033 ......................................................................................................................... 55-7-9 FAULT CODE INST 10034 ....................................................................................................................... 55-7-10 FAULT CODE INST 10035 ....................................................................................................................... 55-7-10 FAULT CODE INST 10036 ....................................................................................................................... 55-7-11 FAULT CODE INST 10037 ....................................................................................................................... 55-7-11 FAULT CODE INST 10038 ....................................................................................................................... 55-7-12 FAULT CODE INST 11011 ....................................................................................................................... 55-7-13 FAULT CODE INST 12011 ....................................................................................................................... 55-7-15 FAULT CODE INST 12021 ....................................................................................................................... 55-7-18 FAULT CODE INST 12022 ....................................................................................................................... 55-7-20 FAULT CODE INST 12023 ....................................................................................................................... 55-7-22 FAULT CODE INST 12031 ....................................................................................................................... 55-7-25 FAULT CODE INST 12043 ....................................................................................................................... 55-7-28 FAULT CODE INST 12051 ....................................................................................................................... 55-7-30 FAULT CODE INST 12061 ....................................................................................................................... 55-7-31 FAULT CODE INST 12071 ....................................................................................................................... 55-7-34 FAULT CODE INST 12091 ....................................................................................................................... 55-7-37 FAULT CODE INST 12101 ....................................................................................................................... 55-7-40 FAULT CODE INST 12111 ....................................................................................................................... 55-7-42 FAULT CODE INST 12121 ....................................................................................................................... 55-7-44 FAULT CODE INST 13010 ....................................................................................................................... 55-7-45 FAULT CODE INST 13011 ....................................................................................................................... 55-7-45 FAULT CODE INST 13012 ....................................................................................................................... 55-7-45 FAULT CODE INST 13021 ....................................................................................................................... 55-7-46 FAULT CODE INST 13022 ....................................................................................................................... 55-7-47 FAULT CODE INST 13031 ....................................................................................................................... 55-7-49 FAULT CODE INST 13032 ....................................................................................................................... 55-7-50 FAULT CODE INST 13040 ....................................................................................................................... 55-7-51 FAULT CODE INST 13044 ....................................................................................................................... 55-7-52 FAULT CODE INST 13051 ....................................................................................................................... 55-7-53 FAULT CODE INST 13052 ....................................................................................................................... 55-7-53 FAULT CODE INST 53001 ....................................................................................................................... 55-7-54 FAULT CODE INST 53002 ....................................................................................................................... 55-7-54 FAULT CODE INST 65535 ....................................................................................................................... 55-7-54
  • 29. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 29 AUX67 CONTROLLER FAULT CODES (FOR REMOTE VALVE SECTIONS 6 & 7)....................................SECTION 55, CHAPTER 8 (Book 8 - 87525649) FAULT CODE AUX67 8012 ........................................................................................................................ 55-8-5 FAULT CODE AUX67 9009 ........................................................................................................................ 55-8-6 FAULT CODE AUX67 9019 ........................................................................................................................ 55-8-7 FAULT CODE AUX67 9029 ........................................................................................................................ 55-8-8 FAULT CODE AUX67 9039 ........................................................................................................................ 55-8-9 FAULT CODE AUX67 11011 .................................................................................................................... 55-8-10 FAULT CODE AUX67 11012 .................................................................................................................... 55-8-11 FAULT CODE AUX67 11021 .................................................................................................................... 55-8-12 FAULT CODE AUX67 11022 .................................................................................................................... 55-8-12 FAULT CODE AUX67 11061 .................................................................................................................... 55-8-14 FAULT CODE AUX67 11062 .................................................................................................................... 55-8-15 FAULT CODE AUX67 11071 .................................................................................................................... 55-8-16 FAULT CODE AUX67 11072 .................................................................................................................... 55-8-17 FAULT CODE AUX67 11081 .................................................................................................................... 55-8-18 FAULT CODE AUX67 11082 .................................................................................................................... 55-8-19 FAULT CODE AUX67 11091 .................................................................................................................... 55-8-20 FAULT CODE AUX67 11092 .................................................................................................................... 55-8-21 FAULT CODE AUX67 11111 .................................................................................................................... 55-8-22 FAULT CODE AUX67 11112 .................................................................................................................... 55-8-23 FAULT CODE AUX67 11121 .................................................................................................................... 55-8-24 FAULT CODE AUX67 11122 .................................................................................................................... 55-8-25 FAULT CODE AUX67 11131 .................................................................................................................... 55-8-26 FAULT CODE AUX67 11132 .................................................................................................................... 55-8-27 FAULT CODE AUX67 11141 .................................................................................................................... 55-8-28 FAULT CODE AUX67 11142 .................................................................................................................... 55-8-29 FAULT CODE AUX67 12022 .................................................................................................................... 55-8-30 FAULT CODE AUX67 12023 .................................................................................................................... 55-8-31 FAULT CODE AUX67 12041 .................................................................................................................... 55-8-32 FAULT CODE AUX67 51011 .................................................................................................................... 55-8-35 FAULT CODE AUX67 51012 .................................................................................................................... 55-8-36 FAULT CODE AUX67 51029 .................................................................................................................... 55-8-37 FAULT CODE AUX67 51039 .................................................................................................................... 55-8-38 FAULT CODE AUX67 51049 .................................................................................................................... 55-8-39 FAULT CODE AUX67 51053 .................................................................................................................... 55-8-40 FAULT CODE AUX67 51054 .................................................................................................................... 55-8-41 FAULT CODE AUX67 51055 .................................................................................................................... 55-8-42 FAULT CODE AUX67 51056 .................................................................................................................... 55-8-43 FAULT CODE AUX67 51063 .................................................................................................................... 55-8-44 FAULT CODE AUX67 51064 .................................................................................................................... 55-8-45 FAULT CODE AUX67 510565 .................................................................................................................. 55-8-46 FAULT CODE AUX67 51066 .................................................................................................................... 55-8-47 FAULT CODE AUX67 51261 .................................................................................................................... 55-8-48 FAULT CODE AUX67 51262 .................................................................................................................... 55-8-49 FAULT CODE AUX67 51301 .................................................................................................................... 55-8-50 FAULT CODE AUX67 51302 .................................................................................................................... 55-8-51 FAULT CODE AUX67 51401 .................................................................................................................... 55-8-52 FAULT CODE AUX67 51402 .................................................................................................................... 55-8-53 FAULT CODE AUX67 51509 .................................................................................................................... 55-8-54 FAULT CODE AUX67 65535 .................................................................................................................... 55-8-55
  • 30. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 30 BATTERY SERVICING AND TESTING.........................................SECTION 55, CHAPTER 9 (Book 8 - 87525649) SAFETY RULES ......................................................................................................................................... 55-9-3 SPECIFICATIONS ...................................................................................................................................... 55-9-4 ACCESS TO BATTERIES .......................................................................................................................... 55-9-5 TJ280/330 and T9010/9020 Tractors ........................................................................................................ 55-9-5 TJ380/430/480/530 and T9030/40/50/60 Tractors .................................................................................... 55-9-6 REMOVAL AND INSTALLATION OF BATTERIES .................................................................................... 55-9-7 To remove batteries .................................................................................................................................. 55-9-7 To install batteries ..................................................................................................................................... 55-9-7 BATTERY MAINTENANCE ........................................................................................................................ 55-9-7 Electrolyte Level ........................................................................................................................................ 55-9-7 Inspecting And Cleaning A Battery ........................................................................................................... 55-9-7 Battery Condition Check ........................................................................................................................... 55-9-8 Specific Gravity Check .............................................................................................................................. 55-9-8 Procedure ................................................................................................................................................ 55-9-10 Three Minute Charge Test ...................................................................................................................... 55-9-11 Testing Battery Cells With Cadmium Probes .......................................................................................... 55-9-12 Battery Leakage Test .............................................................................................................................. 55-9-14 Battery Fast Charging ............................................................................................................................. 55-9-14 Battery Charging ..................................................................................................................................... 55-9-15 Activating Charged Batteries..................................................................................................................... 55-9-15 TRANSMISSION CONTROLLER FAULT CODES .......................SECTION 55, CHAPTER 10 (Book 9 - 84257313 (T9020, 30, 40, 50, and 9060 Series After S/N Z7F204001) FAULT CODE TRANS 11 ......................................................................................................................... 55-10-4 FAULT CODE TRANS 12 ......................................................................................................................... 55-10-5 FAULT CODE TRANS 24 ......................................................................................................................... 55-10-6 FAULT CODE TRANS 37 ......................................................................................................................... 55-10-7 FAULT CODE TRANS 38 ......................................................................................................................... 55-10-8 FAULT CODE TRANS 47 ......................................................................................................................... 55-10-9 FAULT CODE TRANS 48 ....................................................................................................................... 55-10-11 FAULT CODE TRANS 50 ....................................................................................................................... 55-10-12 FAULT CODE TRANS 51 ....................................................................................................................... 55-10-13 FAULT CODE TRANS 52 ....................................................................................................................... 55-10-14 FAULT CODE TRANS 53 ....................................................................................................................... 55-10-15 FAULT CODE TRANS 54 ....................................................................................................................... 55-10-17 FAULT CODE TRANS 59 ....................................................................................................................... 55-10-19 FAULT CODE TRANS 60 ....................................................................................................................... 55-10-20 FAULT CODE TRANS 66 ....................................................................................................................... 55-10-22 FAULT CODE TRANS 67 ....................................................................................................................... 55-10-23 FAULT CODE TRANS 68 ....................................................................................................................... 55-10-24 FAULT CODE TRANS 69 ....................................................................................................................... 55-10-25 FAULT CODE TRANS 70 ....................................................................................................................... 55-10-26 FAULT CODE TRANS 73 ....................................................................................................................... 55-10-27 FAULT CODE TRANS 74 ....................................................................................................................... 55-10-28 FAULT CODE TRANS 75 ....................................................................................................................... 55-10-29 FAULT CODE TRANS 76 ....................................................................................................................... 55-10-30 FAULT CODE TRANS 77 ....................................................................................................................... 55-10-31 FAULT CODE TRANS 80 ....................................................................................................................... 55-10-32 FAULT CODE TRANS 81 ....................................................................................................................... 55-10-34 FAULT CODE TRANS 83 ....................................................................................................................... 55-10-36 FAULT CODE TRANS 103 ..................................................................................................................... 55-10-37 FAULT CODE TRANS 104 ..................................................................................................................... 55-10-38 FAULT CODE TRANS 105 ..................................................................................................................... 55-10-39 FAULT CODE TRANS 106 ..................................................................................................................... 55-10-40 FAULT CODE TRANS 107 ..................................................................................................................... 55-10-41 FAULT CODE TRANS 108 ..................................................................................................................... 55-10-42
  • 31. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 31 FAULT CODE TRANS 109 ..................................................................................................................... 55-10-43 FAULT CODE TRANS 110 ..................................................................................................................... 55-10-44 FAULT CODE TRANS 111 ..................................................................................................................... 55-10-45 FAULT CODE TRANS 112 ..................................................................................................................... 55-10-46 FAULT CODE TRANS 113 ..................................................................................................................... 55-10-47 FAULT CODE TRANS 114 ..................................................................................................................... 55-10-48 FAULT CODE TRANS 115 ..................................................................................................................... 55-10-49 FAULT CODE TRANS 116 ..................................................................................................................... 55-10-50 FAULT CODE TRANS 117 ..................................................................................................................... 55-10-51 FAULT CODE TRANS 118 ..................................................................................................................... 55-10-52 FAULT CODE TRANS 119 ..................................................................................................................... 55-10-53 FAULT CODE TRANS 120 ..................................................................................................................... 55-10-54 FAULT CODE TRANS 122 ..................................................................................................................... 55-10-55 FAULT CODE TRANS 123 ..................................................................................................................... 55-10-56 FAULT CODE TRANS 125 ..................................................................................................................... 55-10-57 FAULT CODE TRANS 126 ..................................................................................................................... 55-10-58 FAULT CODE TRANS 127 ..................................................................................................................... 55-10-59 FAULT CODE TRANS 128 ..................................................................................................................... 55-10-60 FAULT CODE TRANS 129 ..................................................................................................................... 55-10-61 FAULT CODE TRANS 130 ..................................................................................................................... 55-10-62 FAULT CODE TRANS 131 ..................................................................................................................... 55-10-63 FAULT CODE TRANS 132 ..................................................................................................................... 55-10-64 FAULT CODE TRANS 133 ..................................................................................................................... 55-10-65 FAULT CODE TRANS 135 ..................................................................................................................... 55-10-66 FAULT CODE TRANS 136 ..................................................................................................................... 55-10-68 FAULT CODE TRANS 137 ..................................................................................................................... 55-10-70 FAULT CODE TRANS 139 ..................................................................................................................... 55-10-71 FAULT CODE TRANS 140 ..................................................................................................................... 55-10-72 FAULT CODE TRANS 141 ..................................................................................................................... 55-10-73 FAULT CODE TRANS 143 ..................................................................................................................... 55-10-74 FAULT CODE TRANS 144 ..................................................................................................................... 55-10-75 FAULT CODE TRANS 145 ..................................................................................................................... 55-10-76 FAULT CODE TRANS 146 ..................................................................................................................... 55-10-77 FAULT CODE TRANS 147 ..................................................................................................................... 55-10-78 FAULT CODE TRANS 148 ..................................................................................................................... 55-10-80 ARMREST CONTROLLER FAULT CODES ................................SECTION 55, CHAPTER 11 (Book 9 - 84257313) (T9020, 30, 40, 50, and 9060 Series After S/N Z7F204001) FAULT CODE ARM 19 ............................................................................................................................. 55-11-4 FAULT CODE ARM 29 ............................................................................................................................. 55-11-5 FAULT CODE ARM 39 ............................................................................................................................. 55-11-6 FAULT CODE ARM 49 ............................................................................................................................. 55-11-7 FAULT CODE ARM 59 ............................................................................................................................. 55-11-9 FAULT CODE ARM 69 ........................................................................................................................... 55-11-10 FAULT CODE ARM 79 ........................................................................................................................... 55-11-11 FAULT CODE ARM 89 ........................................................................................................................... 55-11-12 FAULT CODE ARM 99 ........................................................................................................................... 55-11-13 FAULT CODE ARM 109 ......................................................................................................................... 55-11-14 FAULT CODE ARM 119 ......................................................................................................................... 55-11-15 FAULT CODE ARM 129 ......................................................................................................................... 55-11-16 FAULT CODE ARM 139 ......................................................................................................................... 55-11-17 FAULT CODE ARM 149 ......................................................................................................................... 55-11-18 FAULT CODE ARM 159 ......................................................................................................................... 55-11-19 FAULT CODE ARM 169 ......................................................................................................................... 55-11-20 FAULT CODE ARM 1019 ....................................................................................................................... 55-11-21 FAULT CODE ARM 1029 ....................................................................................................................... 55-11-22 FAULT CODE ARM 1039 ....................................................................................................................... 55-11-23
  • 32. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 32 FAULT CODE ARM 1049 ....................................................................................................................... 55-11-24 FAULT CODE ARM 1059 ....................................................................................................................... 55-11-25 FAULT CODE ARM 1069 ....................................................................................................................... 55-11-26 FAULT CODE ARM 1079 ....................................................................................................................... 55-11-27 FAULT CODE ARM 1109 ....................................................................................................................... 55-11-28 FAULT CODE ARM 1119 ....................................................................................................................... 55-11-29 FAULT CODE ARM 1129 ....................................................................................................................... 55-11-30 FAULT CODE ARM 1139 ....................................................................................................................... 55-11-31 FAULT CODE ARM 1149 ....................................................................................................................... 55-11-32 FAULT CODE ARM 8011 ....................................................................................................................... 55-11-33 FAULT CODE ARM 9011 ....................................................................................................................... 55-11-34 FAULT CODE ARM 9012 ....................................................................................................................... 55-11-35 FAULT CODE ARM 9013 ....................................................................................................................... 55-11-36 FAULT CODE ARM 9014 ....................................................................................................................... 55-11-37 FAULT CODE ARM 9015 ....................................................................................................................... 55-11-38 FAULT CODE ARM 9021 ....................................................................................................................... 55-11-39 FAULT CODE ARM 9031 ....................................................................................................................... 55-11-40 FAULT CODE ARM 9041 ....................................................................................................................... 55-11-41 FAULT CODE ARM 10091 ..................................................................................................................... 55-11-42 FAULT CODE ARM 12013 ..................................................................................................................... 55-11-43 FAULT CODE ARM 12081 ..................................................................................................................... 55-11-45 FAULT CODE ARM 65535 ..................................................................................................................... 55-11-47 INSTRUMENTATION CONTROLLER FAULT CODES ................SECTION 55, CHAPTER 12 (Book 9 - 84257313 (T9020, 30, 40, 50, and 9060 Series After S/N Z7F204001) FAULT CODE INST 1015 ......................................................................................................................... 55-12-5 FAULT CODE INST 1024 ......................................................................................................................... 55-12-6 FAULT CODE INST 1034 ......................................................................................................................... 55-12-7 FAULT CODE INST 1044 ......................................................................................................................... 55-12-8 FAULT CODE INST 3010 ......................................................................................................................... 55-12-9 FAULT CODE INST 3020 ....................................................................................................................... 55-12-10 FAULT CODE INST 3022 ....................................................................................................................... 55-12-11 FAULT CODE INST 5010 ....................................................................................................................... 55-12-12 FAULT CODE INST 5011 ....................................................................................................................... 55-12-13 FAULT CODE INST 7034 ....................................................................................................................... 55-12-14 FAULT CODE INST 10031 ..................................................................................................................... 55-12-15 FAULT CODE INST 10032 ..................................................................................................................... 55-12-16 FAULT CODE INST 10033 ..................................................................................................................... 55-12-17 FAULT CODE INST 10034 ..................................................................................................................... 55-12-18 FAULT CODE INST 10035 ..................................................................................................................... 55-12-19 FAULT CODE INST 10036 ..................................................................................................................... 55-12-20 FAULT CODE INST 10037 ..................................................................................................................... 55-12-21 FAULT CODE INST 10038 ..................................................................................................................... 55-12-22 FAULT CODE INST 11011 ..................................................................................................................... 55-12-23 FAULT CODE INST 11021 ..................................................................................................................... 55-12-24 FAULT CODE INST 11022 ..................................................................................................................... 55-12-25 FAULT CODE INST 12011 ..................................................................................................................... 55-12-26 FAULT CODE INST 12021 ..................................................................................................................... 55-12-29 FAULT CODE INST 12022 ..................................................................................................................... 55-12-31 FAULT CODE INST 12023 ..................................................................................................................... 55-12-33 FAULT CODE INST 12031 ..................................................................................................................... 55-12-36 FAULT CODE INST 12043 ..................................................................................................................... 55-12-39 FAULT CODE INST 12051 ..................................................................................................................... 55-12-41 FAULT CODE INST 12061 ..................................................................................................................... 55-12-42 FAULT CODE INST 12071 ..................................................................................................................... 55-12-45 FAULT CODE INST 12091 ..................................................................................................................... 55-12-48 FAULT CODE INST 12101 ..................................................................................................................... 55-12-51
  • 33. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 33 FAULT CODE INST 12111 ..................................................................................................................... 55-12-53 FAULT CODE INST 12121 ..................................................................................................................... 55-12-55 FAULT CODE INST 13010 ..................................................................................................................... 55-12-56 FAULT CODE INST 13011 ..................................................................................................................... 55-12-57 FAULT CODE INST 13012 ..................................................................................................................... 55-12-58 FAULT CODE INST 13021 ..................................................................................................................... 55-12-59 FAULT CODE INST 13022 ..................................................................................................................... 55-12-60 FAULT CODE INST 13031 ..................................................................................................................... 55-12-62 FAULT CODE INST 13032 ..................................................................................................................... 55-12-63 FAULT CODE INST 13033 ..................................................................................................................... 55-12-65 FAULT CODE INST 13034 ..................................................................................................................... 55-12-66 FAULT CODE INST 13040 ..................................................................................................................... 55-12-67 FAULT CODE INST 13044 ..................................................................................................................... 55-12-68 FAULT CODE INST 13051 ..................................................................................................................... 55-12-69 FAULT CODE INST 13052 ..................................................................................................................... 55-12-70 FAULT CODE INST 53001 ..................................................................................................................... 55-12-71 FAULT CODE INST 53002 ..................................................................................................................... 55-12-72 FAULT CODE INST 53005 ..................................................................................................................... 55-12-73 FAULT CODE INST 65535 ..................................................................................................................... 55-12-74 CAB REMOVAL - TJ280/330 .........................................................SECTION 90, CHAPTER 1 (Book 8 - 87525649) SPECIAL TOOLS ........................................................................................................................................ 90-1-3 SPECIAL TORQUE VALUES ..................................................................................................................... 90-1-3 CAB REMOVAL .......................................................................................................................................... 90-1-4 CAB INSTALLATION ................................................................................................................................ 90-1-11 CAB REMOVAL - TJ380/430/480/530 ...........................................SECTION 90, CHAPTER 2 (Book 8 - 87525649) SPECIAL TOOLS ........................................................................................................................................ 90-2-3 SPECIAL TORQUE VALUES ..................................................................................................................... 90-2-3 CAB REMOVAL .......................................................................................................................................... 90-2-4 CAB INSTALLATION ................................................................................................................................ 90-2-13 HOOD REMOVAL AND INSTALLATION - TJ280/330...................SECTION 90, CHAPTER 3 (Book 8 - 87525649) SPECIAL TORQUE VALUES ..................................................................................................................... 90-3-2 RECOMMENDED TOOLS .......................................................................................................................... 90-3-2 HOOD REMOVAL ....................................................................................................................................... 90-3-3 HOOD INSTALLATION ............................................................................................................................... 90-3-5 HOOD REMOVAL AND INSTALLATION - TJ480/530...................SECTION 90, CHAPTER 4 (Book 8 - 87525649) SPECIAL TORQUE VALUES ..................................................................................................................... 90-4-2 RECOMMENDED TOOLS .......................................................................................................................... 90-4-2 HOOD REMOVAL ...................................................................................................................................... 90-4-3 HOOD INSTALLATION ............................................................................................................................... 90-4-5 HOOD REMOVAL AND INSTALLATION - TJ380/430...................SECTION 90, CHAPTER 5 (Book 8 - 87525649) SPECIAL TORQUE VALUES ..................................................................................................................... 90-5-2 RECOMMENDED TOOLS .......................................................................................................................... 90-5-2 HOOD REMOVAL ....................................................................................................................................... 90-5-3 HOOD INSTALLATION ............................................................................................................................... 90-5-6 CAB TOP REMOVAL AND INSTALLATION..................................SECTION 90, CHAPTER 6 (Book 8 - 87525649) CAB TOP REMOVAL ................................................................................................................................. 90-6-3 CAB TOP INSTALLATION .......................................................................................................................... 90-6-5
  • 34. TJ AND T9000 MASTER TABLE OF CONTENTS 84257311 - 34 CAB REMOVAL, T9030, 9040, 9050, and 9060 TRACTORS S/N Z7F204001 AND AFTER................................. SECTION 90, CHAPTER 7 (Book 7A - 87740919) SPECIAL TOOLS ........................................................................................................................................ 90-7-3 SPECIAL TORQUE VALUES ..................................................................................................................... 90-7-3 CAB REMOVAL .......................................................................................................................................... 90-7-4 General Information .................................................................................................................................. 90-7-4 CAB INSTALLATION ................................................................................................................................ 90-7-15
  • 35. Section 10 - Engine - Chapter 1 10-1-4 ENGINE REMOVAL STEP 1 1. Park the tractor on a hard level surface. 2. Place the shift lever in PARK (Powershift) or place the shift levers in neutral. 3. Shut off the engine and remove the key from the switch. 4. If necessary, drain the oil from the engine crankcase. STEP 2 See Hood Removal And Installation in this manual and remove the hood from the tractor. STEP 3 See A/C Component Service for instructions to discharge the air conditioning system. STEP 4 See Radiator, Coolers And Condenser Removal And Installation in this manual for instructions to drain and remove the radiator and cooler assembly. STEP 5 MD05M069 Open the battery access door and remove the negative battery cables from the three batteries. STEP 6 MD05N084 Loosen the air cleaner outlet flex tube clamps. STEP 7 MD05N086 Loosen the turbo inlet elbow clamp. STEP 8 MD05N085 Remove the U-clamp (1) from the air cleaner to turbo inlet tube assembly (2). Remove the assembly from the tractor. 2 12
  • 36. Section 10 - Engine - Chapter 1 10-1-5 STEP 9 MD05N087 Open the six latches (1) and remove the air cleaner cover (2) and air filter. STEP 10 MD05N089 Remove the heat shield rear mounting bolt. STEP 11 MD05N088 Remove the heat shield two front mounting bolts (1) and nuts. Remove the heat shield assembly (2). STEP 12 MD05N090 Remove the exhaust pipe U-clamp assembly. STEP 13 MD05N092 Loosen the exhaust pipe band clamp. STEP 14 MD05N091 Loosen the turbo exhaust flex tube clamp (1) and remove the flex tube/exhaust pipe assembly (2). 1 2 1 2 1 2
  • 37. Section 10 - Engine - Chapter 1 10-1-6 STEP 15 MD05N093 Loosen the air cleaner inlet coupler clamps (1) and move the coupler (2) up and off the air cleaner housing (3). STEP 16 MD05N095 Loosen the hose clamps (1) and remove the aspirator tube (2) from the check valve and air cleaner housing. STEP 17 MD05N094 Remove the three RH and three LH air cleaner mounting bolts and remove the air cleaner housing. STEP 18 MD05N097 Remove the bolt, washers and nut from the P-clamp on the rear of the RH inside frame platform. STEP 19 MD05N098 Remove the nut from the platform brace carriage bolt. STEP 20 MD05N096 Remove the three platform to frame mounting bolts, washers and nuts. Remove the platform from the tractor. 1 2 3 1 2 1 1
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  • 39. Section 10 - Engine - Chapter 1 10-1-7 STEP 21 MD05N102 Remove the nut bolt and washer and remove the platform brace. NOTE: It is not necessary to remove the brace to remove the engine, but it will allow easier access to other components. STEP 22 MD05N103 Remove the two deaeration hoses (1) from the tank and remove the P-clamp (2) from the hood support frame. Remove the make up hose (3) from the tank. STEP 23 MD05N056 Remove the overflow hose (1) from the deaeration tank. Remove the hose P-clamp (2) from the tank base. STEP 24 MD05N105 Install lifting straps (1) on the hood support assembly as shown. Attach the straps to an overhead hoist (2) and support the assembly. STEP 25 MD05N100 Mark the position of the bracket on the frame. Remove the two LH front hood support bracket mounting bolts, washers and nuts. 1 1 3 2 1 2 2 1 1 1
  • 40. Section 10 - Engine - Chapter 1 10-1-8 STEP 26 MD05N101 Mark the position of the bracket on the frame. Remove the two LH rear support bracket mounting bolts and washers. STEP 27 MD05N099 Mark the position of the bracket on the frame. Remove the two RH support bracket mounting bolts, washers and nuts. Remove the hood support assembly from the tractor. STEP 28 MD05N106 Install clamps on the heater hoses. STEP 29 MD05N107 Remove the heater hoses from the engne. STEP 30 MD05N108 Install a clamp (1) on the fuel return hose and remove the hose from the engine (2). STEP 31 MD05N109 Remove the engine wire harness connector from the front frame harness. 1 2
  • 41. Section 10 - Engine - Chapter 1 10-1-9 STEP 32 MD05N110 Remove the two A/C hoses from the compressor. Install plugs in the hose ends and caps on the compressor ports. STEP 33 MD05N111 Carefully move the A/C hoses away from the engine and secure the hoses to the RH trash screen brace. STEP 34 MD05N112 Remove the A/C clutch wire connector (1) from the engine wire harness. Remove the top rear compressor mounting bolt (2) and remove the ground wire (3) from the bolt (2). Install the bolt (2). STEP 35 MD05N114 Remove the alternator wire P-clamp from the engine. STEP 36 MD05N113 Remove the battery cable (1) and exciter wire (2) from the alternator. STEP 37 MD05N115 Remove the heater grid solenoid coil wire connector from the solenoid. 2 3 1 1 2