Complete workshop repair & service manual with electrical wiring diagrams for CNH Case Steyr old 9000 Series Tractors. It's the same service manual used by dealers that guaranteed to be fully functional and intact without any missing page.

This CNH Case Steyr 9000-Series Tractors (9105, 9105a, 9115, 9115a, 9125, 9125a, 9145, 9145a, CS68, CS75, CS78, CS78a, CS86, CS86a, CS94, CS94a, CS100, CS110, CS120, CS130, CS150, M968, M975, M9078, M9078a, M9086, M9086a, M9094, M9094a, WD320, WD420) service & repair manual (including maintenance, overhaul, disassembling & assembling, adjustment, tune-up, operation, inspecting, diagnostic & troubleshooting…) is divided into different sections. Each section covers a specific component or system with detailed illustrations. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. The printer-ready PDF documents work like a charm on all kinds of devices.

“7-96100”
Case Steyr M9078, M9086, M9094 Tractors Service - Training Manual
SVA 7-96101; 161 MB PDF
CASE / CNH / STEYR: 9105, 9115, 9125, 9145, CS68, CS75, CS78, CS78a, CS86, CS86a, CS94, CS94a, CS100, CS110, CS120, CS130, CS150, M968, M975, M9078, M9078a, M9086, M9086a, M9094, M9094a, WD320, WD420

“7-96211”
CNH Österreich 9105, 9115, 9125, 9145 Tractors Service - Training Manual
SVA 7-96212; 233 MB PDF
CASE / CNH / STEYR: 9105, 9105a, 9115, 9115a, 9125, 9125a, 9145, 9145a, CS68, CS75, CS78, CS86, CS94, CS100, CS110, CS120, CS130, CS150

EXCERPT:
2. FLYWHEEL CASING
A. Fitting the flywheel casing
The flywheel casing is centered on the cylinder block by means of two sprung dowel pins. The flywheel casings, which are also available as a spare part, are supplied with the bore holes for the pins.
1. Clean the sealing surfaces between the cylinder block and flywheel housing.
2. Apply sealant (e.g. silicone) to the points shown in the figure.
3. Lift the flywheel casing to the correct position and insert all the bolts.
4. Centre the casing and fit the sprung dowel pins using a mandrel.
5. Tighten the inner ring bolts to a torque of 60 Nm and the outer ring bolts to a torque of 110 Nm.
B. Replacing the rear crankshaft sealing ring
1. Separate the tractor between the engine and power unit.
2. Remove the flywheel.
3. Remove the sealing ring without damaging the crankshaft.
4. Clean the sealing ring seat and grind any burr.
NOTE: If the crankshaft is worn at the sealing ring seat, a 2 mm spacer ring (spare part number 162000020718 can be fitted behind the crankshaft sealing ring.
5. Carefully press the sealing ring in down to the bottom of the flywheel casing using the 1TSW 521 and 1TSW 662 fitting tools.
NOTE: THE ASSEMBLY PROCEDURE MUST BE CARRIED OUT IN A DRY AND OIL-FREE STATE.

01_General
02_Engine
03_Fuel_system
04_Electrical_system
05_Steering_system
06_Transmission
08_Hydraulic_system

7-96100...2
  02_engine...3
    7-69860ge_en...4
    7-98510en...78
      INDEX...79
      SPECIAL TOOLS...82
      FOR THE USER...84
        Engine serial number...84
      SAFETY REGULATIONS...85
      ENGINE DATA...86
        Lifting the engine...86
      TECHNICAL DATA...87
        Cylinder block...87
        Cylinder liners...87
        Cylinder head...87
        Valves, rocker arms and push rods...88
        Camshaft...89
        Crankshaft...89
        Flywheel...90
        crankshaft inertia weight (engine type 420)...90
        Camshaft drive...90
        Con-rods...91
        Pistons, piston rings and piston pins...91
        Lubrication system...92
        Lubrication oil pump (320, 420)...92
        Lubrication oil pump (620)...92
        Thermostat...92
        Coolant temperature switch Coolant temperature transmitter...92
        Cooling water pump (320, 420)...93
        Cooling water pump (620)...93
        Turbo charger...93
        Tightening torques...94
      CONSTRUCTION...95
        General information...95
        Cylinder block...95
        Flywheel casing...95
        Cylinder head...96
        Valve mechanism...96
        Crankshaft drive...96
        Timing gears...97
        Lubrication system...98
        Cooling system...99
        Intake / exhaust system...100
      JOB INSTRUCTIONS...101
        1. CYLINDER BLOCK...101
          A. Measuring the cylinder liner wear...101
          B. Removing the cylinder liner...101
          C. Checking the cylinder block...101
          D. Replacing the camshaft bush...101
          E. Oversize bushes for the camshaft...102
          F. Fitting the plug at the rear camshaft end...104
          G. Fitting the plug at the rear camshaft end after inserting an oversize bush...104
          H. Installing the oil dipstick tube...104
          I. Fitting the cylinder liner...104
        2. FLYWHEEL CASING...106
          A. Fitting the flywheel casing...106
          B. Replacing the rear crankshaft sealing ring...106
        3. CYLINDER HEAD...107
          A. Removing the cylinder head...107
          B. Removing the valves...107
          C. Checking the cylinder head...107
          D. Replacing the valve guides...108
          E. Machining the valve seat...109
          F. Replacing the valve seat rings...109
          G. Grinding the valves...109
          H. Fitting the valves...109
          I. Fitting the cylinder head...110
        4. VALVE MECHANISM...111
          A. Maintenance of the rocker arm system...111
          B. Replacing the camshaft / camshaft gear wheel...111
          C. Checking and adjusting the valve clearance...112
        5. CRANKSHAFT...113
          A. Removing the crankshaft...113
          B. Checking the crankshaft...113
          C. Replacing the crankshaft gear wheels...113
          D. Replacement of the crankshaft ring gear (engine type 420 only)...114
          E. Fitting the crankshaft...114
          F. Crankshaft hub...115
          G. Replacing the crankshaft belt pulley and vibration damper...115
          H. Checking the rubber element in the vibration damper (620/420)...116
        6. CON-RODS AND PISTONS...117
          A. Removing the pistons together with the con-rods...117
          B. Checking and replacing the con-rod bearings...117
          C. Checking the con-rod...117
          D. Con-rod weight groups...118
          E. Checking and replacing the piston rings...119
          F. Checking the pistons...120
          G. Fitting the piston pin...120
          H. Fitting the pistons and con-rods...120
        7. BALANCING UNIT (420)...121
          A. Removing and dismantling the balancing unit...121
          B. Balancing unit maintenance...121
          C. Fitting the balancing unit...121
        8. FLYWHEEL...122
          A. Replacing the starter ring gear on the flywheel...122
          B. Fitting the flywheel...122
        9. TIMING MECHANISM...123
          A. Removing the timing gear case...123
          B. Replacing the intermediate gear wheel bush...123
          C. Fitting the timing gear case...124
          D. Front power take-off / auxiliary drive...125
        10. LUBRICATION SYSTEM...126
          A. Checking the oil pressure valve...126
          B. Removing and checking the oil pump...126
          C. Assembling and fitting the oil pump...127
          D. Fitting the sump...127
          E. Oil cooler...127
          F. Piston cooling nozzles (620)...128
          G. Recommended lubrication oils...128
        11. COOLING SYSTEM...129
          A. Thermostat...129
          B. Repairing the coolant pump...129
          C. Coolant quality requirements...130
        12. INTAKE / EXHAUST SYSTEM...131
          A. Checking the air filter...131
          B. Checking the intake / exhaust system...131
          C. Checking the boost pressure...131
          D. Checking the turbo charger...132
          E. Fitting the turbo charger...133
  03_fuel_system...134
    7-97340...135
  04_electrical_system...155
    7-95391en...156
      SPECIAL TOOLS...158
      TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM...162
        Plug...163
        X9/1...163
        Plug...164
        X9/2...164
        Plug...165
        X9/3...165
        Plug...166
        X9/4...166
        Plug...167
        X9/5...167
        Plug...168
        X9/5...168
        Plug...169
        X9/5...169
        Plug...170
        X9/6...170
        Plug...171
        X9/6...171
      TEST VALUES...172
        1. Frequency to check display of rear PTO shaft speed:...172
        2. Frequencies of speed signal of rear PTO shaft:...172
        3. Frequency to check front PTO shaft speed signal:...172
        4. Frequency to check analogue speed display:...172
        5. Fuel gauge:...173
        6. Engine temperature gauge:...173
        7. Coolant temperature switch S32...173
        8. Compressed air indicator:...173
      OPERATING AND CODING OF THE DIGITAL INSTRUMENT WITH INTEGRATED OPERATING HOURS COUNTER...174
      CALIBRATING THE DRIVING SPEED...175
    7-96680EN...176
      Index for Circuit Diagram...179
      LIST OF PLUGS, LEFT...269
      LIST OF PLUGS, RIGHT...270
      LIST OF PLUGS, REAR...271
      LIST OF PLUGS, INSTRUMENT PANEL...272
      LIST OF PLUGS, RIGHT-HAND SIDE PANEL...273
      LIST OF PLUGS, LEFT-HAND SIDE PANEL...274
      CENTRAL PRINT A12...275
      ROOF PRINT A13...277
      COMPONENT CARRIER, LOW-TOP...279
      COMPONENT CARRIER, ENGINE ELECTRICS...280
      EHR-D PRINT, LEFT, A15...281
      EHR CONTROL CONSOLE PRINT A16...281
      MHR CONTROL CONSOLE PRINT A16...282
      EHR OPERATION A51...282
      EHR-D BOX A55...283
      POWER SHIFT 'E' Box A52...283
      'E' BOX MULTI – JOYSTICK A11/1...284
      E-BOX, REAR PTO SHAFT A50/2...284
      PRINT, SINGLE WINCH A33/1 (PRINT, DOUBLE WINCH A33/2)...285
      EGE CONTROL UNIT A10...285
      AIR CONDITIONING THERMOSTAT SWITCH...286
      BLOWER MOTOR CONTROL A21...286
      AIR CONDITIONING CONTROL A20...286
      RELAYS...287
        Miniature relay: (Messr's. Wehrle)...287
        Miniature relay:...287
        Power relay: (Messr's. Wehrle)...287
        Changeover – micro-relay: (Siemens)...287
        Changeover – micro-relay: (Messrs Wehrle, Siemens)...288
        Changeover – micro-relay: (Bosch)...288
        Timed relay 40 sec's. K4/2/2: (Messr's Wehrle u. Sohn)...288
        Time relays, 3 sec., K4/1/1, K4/1/2:...288
        Control unit 14km/h A9:...288
      SWITCHES...289
        Engine oil pressure switch (S6):...289
        Switch, cooling water temperature (S32):...289
        Start safety switch (S10):...289
        Pressure switches:...289
        Front PTO shaft (S29)...289
        Power shift safety switch (S9):...289
        Safety switch – Air-cond. system (S30):...289
        Compressed air switch (S12):...290
        Reed switches (S40/2,S42,S43):...290
        Reed – changeover relay (S41/1,S41/2):...290
        Stop solenoid (Y12):...290
        Glow plug (E10/1):...290
        Fuel pre-heating thermostatic switch:...290
      POTENTIOMETERS...291
        Air-cond. roof blower motor potentiometer (R11):...291
        Air-cond. potentiometer (R10):...291
        EHR potentiometer (R6/1,R6/2,R6/3,R6/4):...291
        Stepping potentiometer EGE (R8):...291
      SENSORS...292
        EHR position sensor (B9/1):...292
        EHR force measuring bolts (B10/1,B10/2):...292
        Inductive transmitter, driving speed (B6),...292
        Rear PTO shaft speed (B7):...292
        Air-conditioning temperature sensor (R9):...292
        Pressure sensor EGE M2 (B20):...292
      SOLENOID VALVES...293
        Solenoid valve 4-wheel drive (Y1) Power shift (Y3) Rear axle diff. lock (Y10) Front axle differen...293
        Solenoid valve EHR control unit (Y6,Y7):...293
        Solenoid valve (shut-off valve) Auxiliary control unit (Y2/4):...293
        Solenoid valve (directional control valve) Auxiliary control unit (Y2/1,Y2/2,Y2/3):...293
        Solenoid valve EGE (Y2/1, Y2/2):...293
        (Messr's. Wandfluh)...293
        Solenoid valve EGE (Y20, Y21):...293
      INSTRUMENT TEST VALUES...294
      LAMPS AND FUSES...295
      OPERATING AND CODING OF THE DIGITAL INSTRUMENT WITH INTEGRATED OPERATING HOURS COUNTER...296
        General information...296
        Operating / function...296
        Coding...296
        General information...296
        Coding the engine speed indication (operating hours)...296
        Coding the rear PTO shaft speed indication...296
        Coding the rear PTO front speed indication...296
      CALIBRATING THE DRIVING SPEED...297
    7-97390en...298
    7-98691EN...416
      Index for Circuit Diagram...419
        M9078 - M9094 CS78 - CS94...419
      List of Plugs, Left...497
      List of Plugs, Right...498
      List of Plugs (at rear)...499
      List of Plugs – Instrument Panel...500
      List of plugs, roof lining, high-top...501
      List of plugs, roof lining, low-top...501
      List of plugs, EHR, right-hand side panel...502
      List of plugs, EHR, right-hand side panel, with EGE and EFH...503
      List of plugs, MHR, right-hand side panel, with EGE and EFH...504
      List of Plugs – Left-hand Side Panel...505
      Central Print A12...506
      ECCU A60 (Electronic Central Control Unit)...508
      Print – Roof electrics A13...509
      Component carrier – Low-Top...511
      Component Carrier – Engine Electrics...512
      Print – EHR Left, A15 (Distribution Print)...513
      Print, EHR-B Operating Console A16...513
      MHR – Operating Console A16...514
      EHR Control Unit A25...514
      EGE Control Unit A11...515
      EFH print A17...515
      EFH control unit A55/2...516
      4-Wheel Drive Management – Control Unit A10...516
      Blower motor – Control A21...517
      Air-Conditioning – Control A20...517
      Relays...518
      Switch...519
      Potentiometer for...521
      Sensors...522
      Solenoid Valves...524
      Heating elements...526
      Instrument Test Values...527
      Lamps and Fuses...528
      Operation and Coding the Digital Instrument with Integrated operating HoursCounter...529
      Calibrating the speedometer...530
        Page 37...493
        Page 38...495
    7-99220 EN...532
      TABLE OF CONTENTS...533
      GENERAL INFORMATION...534
      ELECTRICAL FITTINGS...535
      OPERATING INSTRUCTIONS SAFETY DEVICES AND PROTECTIVE MEASURES...536
      ECCU – POWER SUPPLY...537
      POWER SHIFT POWER 2 – FUNCTION...538
      EHR CONTROL 'TRANSPORT'...539
      EHR CONTROL 'CONTROL' (LOWER)...540
      EHR CONTROL 'FAST RETRACT'...541
      REAR PTO SHAFT: FUNCTION...542
      REAR PTO SHAFT: SWITCHING ON AND OFF...543
      REAR PTO SHAFT: MANAGEMENT...544
      AUXILIARY CONTROL UNIT – PRESSURE IN CONNECTION 'A' (WITH MULTI-CONTROLLER)...545
      AUXILIARY CONTROL UNIT – PRESSURE IN CONNECTION 'B' (WITH MULTI-CONTROLLER)...546
      AUXILIARY CONTROL UNIT – 'FREEDOM OF MOVEMENT OR FLOATING POSITION' (WITH MULTI-CONTROLLER)...547
      AUXILIARY CONTROL UNIT – PRESSURE IN CONNECTION 'A' (WITH LEVER SWITCH)...548
      AUXILIARY CONTROL UNIT – PRESSURE IN CONNECTION 'B' (WITH LEVER SWITCH)...549
      AUXILIARY CONTROL UNIT – 'FREEDOM OF MOVEMENT OR FLOATING POSITION' (WITH LEVER SWITCH)...550
      4-WHEEL DRIVE (MFD) 'ON' (WITHOUT MANAGEMENT AND OPTISTOP)...551
      4-WHEEL DRIVE (MFD) 'OFF' (WITHOUT MANAGEMENT AND OPTISTOP)...552
      4-WHEEL DRIVE (MFD) 'ON' (WITH MANAGEMENT AND OPTISTOP)...553
      4-WHEEL DRIVE (MFD) 'OFF' (WITH MANAGEMENT AND OPTISTOP)...553
      DIFFERENTIAL LOCK(S) – MANAGEMENT – EHR IN 'CONTROL' FUNCTION...554
      DIFFERENTIAL LOCK(S) – MANAGEMENT – EHR IN 'TRANSPORT' FUNCTION...554
  05_steering_system...556
    7-70620ge_en...557
  06_transmission...595
    7-97150...596
    7-99240en...602
  08_hydraulic_system...750
    6-50640en...751
      FUNCTIONAL DESCRIPTION AND TROUBLESHOOTING...751
        Electronic front hitch control (EFH) M9078, M9086, M9094 CS78, CS86, CS94 from DBD0057987 onwards...751
          ELECTRONIC FRONT HITCH CONTROL (EFH)...753
            Functions...753
            Type of control...753
            General Remarks...753
          COMPONENTS...754
            4...754
          GENERAL DESCRIPTION...755
          OPERATING CONTROLS...756
          1. Multi-Controller...757
            1...757
          2. Indicator lamp IMPLEMENT LOAD RELIEF (green)...757
            2...757
          3. Indicator lamp DIAGNOSIS (red)...757
            3...757
          4. RAISE / TRANSPORT button...758
            4...758
          5. LOWER / CONTROL button...758
            5...758
          6. Setpoint stepping switch...759
          7. Potentiometer for mixed control...760
          8. Potentiometer for lift limitation...761
          9. Potentiometer for lowering speed...762
          10. RAISE / LOWER button (in the cab)...763
            10...763
          11. Front operation...763
            1...763
          12. Changeover switch (latchable) for RAISE/AUTO (Automatic) operatingmode...763
            12...763
          13. Safety switch (latchable)...764
            13...764
          POSITION CONTROL FUNCTION...765
            4...765
          PRESSURE CONTROL FUNCTION...766
            4...766
          CALIBRATION...767
          OSCILLATION DAMPING...768
          EMERGENCY OPERATION...769
            2...769
          POSITION SENSOR...770
            Construction and function...770
            Characteristic curve...771
            Technical Data...771
          Adjusting the Position Sensor...772
            PRESSURE SENSOR...773
              Function:...773
              Technical Data...774
            RESERVOIR BLOCK (complete)...775
              3...775
            EFH LINE PLAN – EHR version...776
            EFH LINE PLAN – MHR version...778
            EFH CONTROL VALVE SB 23-OC...780
              4...780
          Technical data:...780
            NEUTRAL function...781
              4...781
            RAISE function...782
              2...782
            LOWER function...783
              3...783
            EFH CONTROL VALVE SB 23-LS...784
              3...784
            NEUTRAL function...784
            RAISE function...785
              10...785
            LOWER function...786
              7...786
            DIAGNOSIS...787
          General...787
          Fault code display...787
          Fault code assignment...787
          Minor faults...787
          Fairly serious faults...787
          Serious faults...787
          Remedying of faults...787
            Fault codes...788
          MINOR FAULTS...788
          FAIRLY SERIOUS FAULTS...789
          SERIOUS FAULTS...790
            Pin assignment, plug X55 (EFH box A55/2)...791
          Plug X55...792
            TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM...793
          General...793
          Test conditions...793
          Measuring procedure (example)...793
          Parts of the diagnostic system required...793
          LOAD RELIEF signal...796
    7-95350en...801
    7-99420EN...895
      EHR-B ELECTRONIC LIFTING GEAR CONTROL SYSTEM...899
        Functions of the EHR-B...899
        General Remarks...899
        EHR-B COMPONENTS...900
        EHR-B OPERATION...901
        FUNCTIONAL DESCRIPTION (WITHOUT MULTI-CONTROLLER)...902
          1. Raise switch (without multi-controller):...903
        FUNCTIONAL DESCRIPTION (WITH MULTI-CONTROLLER)...904
          1. Buttons for Transport and Control on the Multi-Controller:...905
          2. Setpoint adjusting wheel:...906
          3. Pulling power control:...907
          4. Lift Limiting:...908
          5. Lowering speed:...909
        BASIC FUNCTIONS OF THE EHR FOR POSITION CONTROL...910
        BASIC FUNCTIONS OF THE EHR FOR PULLING POWER CONTROL...911
        OSCILLATION DAMPING...912
          Deactivating oscillation damping...914
          6. Light emitting diodes:...914
          7. Stop button:...914
          8. Safety switch:...914
          9. Traction control indicator lamp:...915
          10. Diagnosis display:...915
          11. Rear operating position:...915
        EMERGENCY OPERATION...916
        DIGITAL, INDUCTIVE POSITION SENSOR...917
          Position sensor – Technical Data and Characteristics...918
          Adjusting the Position Sensor...919
        POWER SENSORS – DESIGN AND INSTALLATION...920
          Power Sensor – Technical Data and Signal Shaping...921
        ELECTRONIC CONTROL UNIT (with management functions)...922
        HIGH PRESSURE HYDRAULIC CIRCUIT...924
        CONTROL VALVE EHR 5-OC...926
          NEUTRAL FUNCTION – GRAPHIC 2...928
          RAISE FUNCTION – GRAPHIC 3...930
          LOWER FUNCTION – GRAPHIC 5 AND GRAPHIC 6...932
        EHR-B DIAGNOSIS...934
      FAULT CODE LIST...935
        SERIOUS FAULTS...935
        MEDIUM FAULTS...935
        SLIGHT FAULTS...936
        PIN ASSIGNMENT OF EHR-B BOX A25...937
      TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM...938
  7-96111EN...945
7-96211...946
  02_engine...947
    7-70670...948
    7-98510en...1045
      INDEX...1046
      SPECIAL TOOLS...1049
      FOR THE USER...1051
        Engine serial number...1051
      SAFETY REGULATIONS...1052
      ENGINE DATA...1053
        Lifting the engine...1053
      TECHNICAL DATA...1054
        Cylinder block...1054
        Cylinder liners...1054
        Cylinder head...1054
        Valves, rocker arms and push rods...1055
        Camshaft...1056
        Crankshaft...1056
        Flywheel...1057
        crankshaft inertia weight (engine type 420)...1057
        Camshaft drive...1057
        Con-rods...1058
        Pistons, piston rings and piston pins...1058
        Lubrication system...1059
        Lubrication oil pump (320, 420)...1059
        Lubrication oil pump (620)...1059
        Thermostat...1059
        Coolant temperature switch Coolant temperature transmitter...1059
        Cooling water pump (320, 420)...1060
        Cooling water pump (620)...1060
        Turbo charger...1060
        Tightening torques...1061
      CONSTRUCTION...1062
        General information...1062
        Cylinder block...1062
        Flywheel casing...1062
        Cylinder head...1063
        Valve mechanism...1063
        Crankshaft drive...1063
        Timing gears...1064
        Lubrication system...1065
        Cooling system...1066
        Intake / exhaust system...1067
      JOB INSTRUCTIONS...1068
        1. CYLINDER BLOCK...1068
          A. Measuring the cylinder liner wear...1068
          B. Removing the cylinder liner...1068
          C. Checking the cylinder block...1068
          D. Replacing the camshaft bush...1068
          E. Oversize bushes for the camshaft...1069
          F. Fitting the plug at the rear camshaft end...1071
          G. Fitting the plug at the rear camshaft end after inserting an oversize bush...1071
          H. Installing the oil dipstick tube...1071
          I. Fitting the cylinder liner...1071
        2. FLYWHEEL CASING...1073
          A. Fitting the flywheel casing...1073
          B. Replacing the rear crankshaft sealing ring...1073
        3. CYLINDER HEAD...1074
          A. Removing the cylinder head...1074
          B. Removing the valves...1074
          C. Checking the cylinder head...1074
          D. Replacing the valve guides...1075
          E. Machining the valve seat...1076
          F. Replacing the valve seat rings...1076
          G. Grinding the valves...1076
          H. Fitting the valves...1076
          I. Fitting the cylinder head...1077
        4. VALVE MECHANISM...1078
          A. Maintenance of the rocker arm system...1078
          B. Replacing the camshaft / camshaft gear wheel...1078
          C. Checking and adjusting the valve clearance...1079
        5. CRANKSHAFT...1080
          A. Removing the crankshaft...1080
          B. Checking the crankshaft...1080
          C. Replacing the crankshaft gear wheels...1080
          D. Replacement of the crankshaft ring gear (engine type 420 only)...1081
          E. Fitting the crankshaft...1081
          F. Crankshaft hub...1082
          G. Replacing the crankshaft belt pulley and vibration damper...1082
          H. Checking the rubber element in the vibration damper (620/420)...1083
        6. CON-RODS AND PISTONS...1084
          A. Removing the pistons together with the con-rods...1084
          B. Checking and replacing the con-rod bearings...1084
          C. Checking the con-rod...1084
          D. Con-rod weight groups...1085
          E. Checking and replacing the piston rings...1086
          F. Checking the pistons...1087
          G. Fitting the piston pin...1087
          H. Fitting the pistons and con-rods...1087
        7. BALANCING UNIT (420)...1088
          A. Removing and dismantling the balancing unit...1088
          B. Balancing unit maintenance...1088
          C. Fitting the balancing unit...1088
        8. FLYWHEEL...1089
          A. Replacing the starter ring gear on the flywheel...1089
          B. Fitting the flywheel...1089
        9. TIMING MECHANISM...1090
          A. Removing the timing gear case...1090
          B. Replacing the intermediate gear wheel bush...1090
          C. Fitting the timing gear case...1091
          D. Front power take-off / auxiliary drive...1092
        10. LUBRICATION SYSTEM...1093
          A. Checking the oil pressure valve...1093
          B. Removing and checking the oil pump...1093
          C. Assembling and fitting the oil pump...1094
          D. Fitting the sump...1094
          E. Oil cooler...1094
          F. Piston cooling nozzles (620)...1095
          G. Recommended lubrication oils...1095
        11. COOLING SYSTEM...1096
          A. Thermostat...1096
          B. Repairing the coolant pump...1096
          C. Coolant quality requirements...1097
        12. INTAKE / EXHAUST SYSTEM...1098
          A. Checking the air filter...1098
          B. Checking the intake / exhaust system...1098
          C. Checking the boost pressure...1098
          D. Checking the turbo charger...1099
          E. Fitting the turbo charger...1100
  03_fuel_system...1101
    7-96660EN...1102
      SPECIAL TOOLS...1104
      GENERAL INFORMATION...1105
      TECHNICAL DATA...1106
        Bosch injection pump...1106
        Oil fill quantity (when fitting injection pump)...1106
        Pump type...1106
        Injection sequence...1106
        Idling speed...1106
        Cut-out solenoid...1106
        Starting-fuel solenoid Y16 (420.80 only)...1106
        Fuel pump...1106
        Stanadyne injection nozzles...1106
        Thermo-start unit...1106
        Tightening torques...1106
      Removal of the injection nozzle mounting...1107
      Checking the injection nozzles...1107
      Overhauling the injection nozzles...1108
      Fitting the injection nozzle mounting into the cylinder head...1108
      Assembly of the injection lines...1108
      Removal of the injection pump...1112
      Installation of the injection pump...1112
        Checking start of delivery...1112
        Readjustment of start of delivery...1113
      B. Installation when gear wheels are fastened without spline...1113
      Bleeding the fuel system of air...1114
      Thermo-start system...1115
      Bleeding the thermo-start system of air...1115
      Measuring the fuel feed pressure...1115
      Checking the overflow valve...1115
      Checking the fuel delivery pump...1116
        Replacing the fuel delivery pump valves...1116
      Adjusting the minimum idling speed...1116
      Fuel quality requirements...1117
      Bio-diesel fuel...1117
      INJECTION NOZZLE MOUNTING...1107
      INJECTION PUMP...1109
    7-99110en...1118
      SPECIAL TOOLS...1121
      GENERAL INFORMATION...1122
      TECHNICAL DATA...1123
        Stanadyne injection pump...1123
        Pump type...1123
        Injection sequence...1123
        Cut-out solenoid...1123
        Fuel pump...1123
        Stanadyne injection nozzles...1123
        Thermo-start unit...1123
        Tightening torques...1123
      FUEL SYSTEM WITH STANADYNE DISTRIBUTOR INJECTION PUMP...1124
        Injection nozzles...1125
          Removing the injection nozzles...1125
          Checking the injection nozzles...1125
          Overhauling the injection nozzles...1126
          Assembly of the injection nozzles in the cylinder head...1126
          Assembly of the injection lines...1126
        Stanadyne distributor injection pump...1127
          Construction of the Stanadyne distributor injection pump...1128
          How the Stanadyne distributor injection pump works...1129
          Removal of the injection pump...1130
        Assembly of the injection pump and adjustment of the delivery start (static)...1130
          Bleeding the fuel system...1131
        Thermo-start system...1131
          Bleeding the thermo-start system...1131
        Adjusting the idling speed...1132
        Measuring the fuel feed pressure...1132
          Testing the fuel pressure...1132
        Checking the delivery start using TIME TRAC (dynamic)...1133
          TIME TRAC setting and check values...1134
          Troubleshooting when using the TIME TRAC...1134
        Fuel quality requirements...1135
          Bio-diesel fuel...1135
  04_electrical_system...1136
    6-50950en...1137
      Index for Circuit Diagram...1140
      List of plugs, left...1228
      List of plugs, right...1229
      List of plugs (at rear)...1230
      List of plugs on instrument carrier...1231
      List of plugs on the right-hand side of the cab...1232
      Central Electrics Print A12...1233
      Print – Roof electrics A13...1236
      Print A14, engine electrics...1238
      Print – EHR Left, A15 (Distribution Print)...1240
      EHR-D Print, operating console, A16...1240
      Print, single/double winch A33/1 and A33/2...1241
      Instrument carrier for low-top version...1242
      Relays...1243
      Components, gearbox electrics / electronics...1244
      Components, electronic 3-point hitch control...1247
      Components, air conditioning system...1249
      Components, engine / fuel system...1251
      Components, sprung front axle...1252
      Components, hydraulics...1253
      Components, brake...1254
      Components, cab...1255
      ECCU – Electronic Central Control Unit...1256
      Test Values...1257
      Lamps and Fuses...1258
      Operation and coding of the digital instrument with integrated operating hours counter...1259
      Calibrating the ”Driving speed” display...1260
    7-70640...1261
    7-95830...1379
      Index for Circuit diagram...1382
      Sheet 1...1384
      Sheet 2...1386
      Sheet 3...1388
      Sheet 4...1390
      Sheet 5...1392
      Sheet 6...1394
      Sheet 7...1396
      Sheet 8...1398
      Sheet 9...1400
      Sheet 10...1402
      Sheet 11...1404
      Sheet 12...1406
      Sheet 13...1408
      Sheet 14...1410
      Sheet 15...1412
      Sheet 16...1414
      Sheet 17...1416
      Sheet 18...1418
      Sheet 19...1420
      Sheet 20...1422
      Sheet 21...1424
      Sheet 22...1426
      Sheet 23...1428
      Sheet 24...1430
      Sheet 25...1432
      Sheet 26...1434
      Sheet 27...1436
      Sheet 28...1438
      Sheet 29...1440
      Sheet 30...1442
      Sheet 31...1444
      Sheet 32...1446
      Sheet 33...1448
      Sheet 34...1450
      Sheet 35...1452
      Sheet 36...1454
      Sheet 37...1456
      Sheet 38...1458
      List of Plugs...1460
      List of Plugs...1461
      List of Plugs (at rear)...1462
      List of Plugs – Instrument Panel...1463
      List of Plugs – Right-hand Side Panel...1464
      Central Electrics Print...1465
      Central Electrics Print...1466
      Print – Roof electrics...1468
      Engine Electrics Print...1470
      EHR-D Print (left)...1472
      EHR-D Print (operating console)...1473
      Single Winch Print...1474
      Relays...1475
      Switches...1476
      Potentiometers...1478
      Sensors...1479
      Solenoid Valves...1481
      ECCU – Electronic Central Control Unit...1483
      Instrument Test Values...1484
      Lamps and Fuses...1485
      Operation and Coding the Digital Instrument with Integrated operatingHours Counter...1486
      Calibrating the speedometer...1487
    7-97221en...1489
  05_steering_system...1515
    7-71500...1516
    7-97101en...1556
      GENERAL DESCRIPTION...1559
      COMPONENTS...1560
      OPERATION...1561
        Main Switch, Suspension ON / OFF...1561
        Auxiliary switch (pushbutton function only, pressed to the left – lower, to the right – raise)...1561
        Indicator lamp on the instrument panel...1561
      FUNCTION OF THE SUSPENSION...1562
        Calibration procedure...1562
        Control Function...1563
      AXLE SENSORS...1564
        General Remarks...1564
        Testing the 'Sensor Settings'...1565
        Adjusting the Sensors...1567
      LOWERING THE FRONT AXLE MANUALLY...1568
      ERROR CODES...1569
      TROUBLESHOOTING USING THE DIAGNOSTIC SYSTEM...1570
        Measurement table...1571
        Test – solenoid valve control...1573
        Circuit Diagram, Sprung Front Axle...1574
      SPECIAL TOOLS...1558
    7-98580en...1576
      TABLE OF CONTENTS...1577
      TECHNICAL DATA...1578
      SPECIAL TIGHTENING TORQUES...1578
      SPECIAL TOOLS...1579
      GENERAL NOTES...1580
      PLANETARY DRIVE...1580
        Removing and Fitting...1580
        Disassembly/Re-assembly...1581
      WHEEL HUB...1582
        Disassembly/Re-assembly...1582
      Sectional drawing through the planetary gear and wheel hub...1584
      PIVOT BEARING HOUSING...1585
        Removing and Fitting...1585
        Disassembly/Re-assembly...1586
      KING PIN HOUSING...1587
        Removing and Fitting...1587
        Disassembly...1591
        Assembly...1593
      Sectional drawing, through the pivot bearing housing and thekingpinhousing...1595
      DRIVE SHAFTS...1596
        Disassembly/Re-assembly...1596
      4-WHEEL DRIVE AXLE...1597
        Removing and Fitting...1597
      PIVOTED BEARING...1600
        Disassembly/Re-assembly...1600
        Disassembly...1601
        Assembly...1603
        Adjusting the Torsion Bars...1607
      AXLE HOUSING...1610
        Disassembly...1610
      DIFFERENTIAL UNIT...1615
        Disassembly...1615
        Assembly...1615
        Adjusting the Pinion Shaft...1617
        Pinion Shaft Unit...1619
        Fitting the Differential Unit...1621
        Adjusting the Crown Wheel Tooth Flank Play...1623
        Adjusting the Differential Bearing Pre-Tension...1624
      TRACK ALIGNMENT...1626
  06_transmission...1628
    7-71450...1629
      Index...2232
      Special Tools, Category 1...2232
      Disassembly...2233
      Re-assembly...2237
      Power shuttle – driving clutch...2237
      Pre-assembling the inner disk carrier...2237
      Adjusting the disk assembly air gap:...2238
      Adjusting the Clutch Shaft and Crawler Gear Synchronisation...2246
  7-96222EN...2251