Case ih magnum 275 tractor service repair manual

service repair manual

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

19. Section
1001
1001

January, 2006
SAFETY, GENERAL INFORMATION /
MAINTENANCE SCHEDULE

20. 1001-3
Template Name: SM_2_col
Template Date: 1994_04_05
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SAFETY
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT
SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE
THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT
FOLLOWS AND BE ALERT TO THE POSSIBILITY OF
PERSONAL INJURY OR DEATH.
M171B !
To prevent injury always follow the Warning, Caution and Danger notes in this section and throughout the manual.
Put the warning tag shown below on the key for the
key switch when servicing or repairing the
machine. One warning tag is supplied with each
machine. Additional tags are available from your
service parts supplier.
Before servicing a machine, park the machine on
hard level ground. Turn off the engine, apply the
parking brake and remove the key from the key
switch. Put blocks in front of and behind either the
front or rear wheels.
WARNING:Read the Operator’s Manual to
familiarize yourself with the correct control
functions.
M489
WARNING: Operate the machine and
equipment controls from the seat position
only. Any other method could result in
serious injury.
M490
WARNING: This machine is for one
operator, no riders allowed.
M491A
201L95
!
!
!
WARNING:Before starting engine study
Operator’s Manual safety messages. Read
all safety signs on machine. Clear the area of
other persons. Learn and practice safe use
of controls before operating. It is your
responsibility to understand and follow
manufacturers instructions on machine
operation, service, and to observe pertinent
laws and regulations. Operator and Service
Manuals may be obtained from your
equipment dealer.
M103A
WARNING: If you wear clothing that is too
loose or do not use the correct safety
equipment for your job, you can be injured.
Always wear clothing that will not catch on
objects. Extra safety equipment that can be
required includes hard hat, safety shoes, ear
protection, eye or face protection, heavy
gloves and reflector clothing.
M492
WARNING: When working in the area of the
fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
M493
WARNING:When doing checks and tests
on the equipment hydraulics, follow the
procedures as they are written. DO NOT
change the procedure.
M494
WARNING: When putting the hydraulic
cylinders on this machine through the
necessary cycles to check operation or to
remove air from a circuit, make sure all
people are out of the way.
M495
!
!
!
!
!

21. 1001-4
Template Name: SM_2_col
Template Date: 1994_04_05
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WARNING:Always wear heat protective
gloves to prevent burning your hands when
handling heated parts.
SM121A
WARNING:Lower all attachments to the
ground or use stands to safely support the
attachments before you do any maintenance
or service.
M496
WARNING: Hydraulic oil or diesel fuel
leaking under pressure can penetrate the
skin and cause infection or other injury.
To Prevent Personal Injury:
Relieve all pressure, before disconnecting
fluid lines. Before applying pressure, make
sure all connections are tight and
components are in good condition.
Never use your hand to check for suspected
leaks under pressure.
Use a piece of cardboard or wood for this
purpose. If injured by leaking fluid, see your
doctor immediately.
SM171A
WARNING:When removing hardened pins
such as a pivot pin, or a hardened shaft, use
a soft head (brass or bronze) hammer or use
a driver made from brass or bronze and a
steel head hammer.
M497
WARNING: When using a hammer to
remove and install pivot pins or separate
parts using compressed air or using a
grinder, wear eye protection that completely
encloses the eyes (approved goggles or
other approved eye protectors).
M498
WARNING: Use suitable floor (service)
jacks or chain hoist to raise wheels or tracks
off the floor. Always block machine in placed
with suitable safety stands.
M499
!
!
!
!
!
!
WARNING:When servicing or repairing the
machine. Keep the shop floor and operator’s
compartment and steps free of oil, water,
grease, tools, etc. Use an oil absorbing
material and or shop cloths as required. Use
safe practices at all times.
M500
WARNING: Some components of this
machine are very heavy. Use suitable lifting
equipment or additional help as instructed in
the Service Manual.
M501
WARNING: Engine exhaust fumes can
cause death. If it is necessary to start the
engine in a closed place, remove the exhaust
fumes from the area with an exhaust pipe
extension. Open the door and get outside air
into the area.
M502
WARNING:When the battery electrolyte is
frozen, the battery can explode if (1), you try
to charge the battery, or (2), you try to jump
start and run the engine. To prevent the
battery electrolyte from freezing, try to keep
the battery at full charge. If you do not follow
these instructions, you or others in the area
can be injured.
M503
WARNING: Batteries contain acid and
explosive gas. Explosions can result from
sparks, flames or wrong cable connections.
To connect the jumper cables correctly to the
battery of this machine see the Operator’s
Manual. Failure to follow these instructions
can cause serious injury or death.
M504
!
!
!
!
!

22. 1001-5
Template Name: SM_2_col
Template Date: 1994_04_05
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GENERAL INFORMATION
Cleaning
Clean all metal parts except bearings, in mineral spirits or by
steam cleaning. Do not use caustic soda for steam cleaning.
After cleaning, dry and put oil on all parts. Clean oil passages
with compressed air.
Inspection
Check all parts when the parts are disassembled. Replace all
parts that have excessive wear or are damaged. Small
scoring or grooves can be removed with a hone or crocus
cloth. Complete visual inspection for indications of wear,
pitting and the replacement of parts necessary will prevent
early failures.
Bearings
Clean bearings with a good clean solvent and permit to air
dry. DO NOT DRY BEARINGS WITH COMPRESSED AIR.
Check bearings for smooth easy action. If the bearing has a
loose fit or rough action, the bearing must be replaced.
Needle Bearings
Before you press needle bearings into a bore, always remove
any metal protrusions in the bore or the edge of the bore.
Before you press bearings into position, put petroleum jelly
on the inside and outside diameter of the bearing.
Gears
Check all gears for excessive wear or damage. Replace gears
as necessary.
Oil Seals, O-rings and Gaskets
Always install new oil seals, O-rings and gaskets. Put
petroleum jelly on seals and O-rings.
Shafts
Check all shafts for excessive wear or damage. Check the
bearing and oil seal surfaces on the shafts for excessive wear
or damage. Replace shafts as necessary.
Service Parts
Always install genuine Case service parts. When ordering
refer to the Parts Catalog for the correct part number of the
genuine Case replacement items. Failures due to the use of
other than genuine Case replacement parts are not covered
by warranty.
Lubrication
Use only the oils and lubrication specified in the Operator’s or
Service Manual. Failures due to the use of non specified oils
and lubricants are not covered by warranty.

23. Section
2001
2001

January, 2006
COOLING SYSTEM MODULE
REMOVAL AND INSTALLATION

24. 2001-3

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

25. 2001-4

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

26. 2001-5

Template Name: SM_2_col
Template Date: 1994_04_05
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STEP 8
Disconnect the upper radiator tube.
STEP 9
Disconnect the lower radiator tube.
STEP 10
Attach lift brackets and a sling to the top of the
radiator.
STEP 11
Remove the four assembly mounting bolts.
RD05E034
RD05E033
RD05E036
RD05E035

27. 2001-6

Template Name: SM_2_col
Template Date: 1994_04_05
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STEP 12
Slide the assembly forward until the fan shroud
clears the fan. Lift the assembly off the tractor.
RD05E037

28. 2001-7

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

29. 2001-8

Template Name: SM_2_col
Template Date: 1994_04_05
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STEP 16
Install the lower radiator tube.
STEP 17
Install the upper radiator tube.
STEP 18
Connect the hydraulic oil cooler inlet and outlet lines.
STEP 19
Connect the horn wire (1), fuel cooler inlet/outlet
lines (2) and the A/C condenser inlet (3) and receiver
dryer outlet (4) lines.
RD05E033
RD05E034
RD05E031
RD05E030
4
2
3
1

30. 2001-9

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

31. 2002-4

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

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33. 2002-5

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

34. 2002-6

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

35. 2002-7

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

36. 2002-8

Template Name: SM_2_col
Template Date: 1994_04_05
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STEP 12
Disconnect the hydraulic cooling lines.
STEP 13
Remove exhaust shield mounting bolts (1) and nut
(2). Remove shield.
STEP 14
Disconnect the exhaust pipe (1) at the turbo outlet (2)
and exhaust elbow inlet (3). Remove the pipe.
RD05E031
RD05E043
1
2
RD05E044
3
2
1