Fu Mig Adora

SPX Series
Patriot Sprayer
SPX 4260
Troubleshooting Manual
86986705
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 DEATH OR SERIOUS INJURY.
M171C
If Safety Decals on this machine use the words Danger, Warning or Caution,
which are defined as follows:
● DANGER: Indicates an immediate hazardous situation that, if not avoided, will

result in death or serious injury. The color associated with Danger is RED.
● WARNING: Indicates a potentially hazardous situation that, if not avoided,

could result in death or serious injury. The color associated with Warning is
ORANGE.
● CAUTION: Indicates an potentially hazardous situation that, if not avoided,

may result in minor or moderate injury. It may also be used to alert against
unsafe practices. The color associated with Caution is YELLOW.
If Safety Decals on this machine are ISO two panel Pictorial, decals are defined
as follows:
● The first panel indicates the nature of the hazard.

● The second panel indicates the appropriate avoidance of the hazard.
● Background color is YELLOW.
● Prohibition symbols such as and STOP if used, are RED.
! WAR NIN G
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR
DEATH. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY
OPERATOR:
● Is instructed in safe and proper use of the machine.
● Reads and understands the Manual(s) pertaining to the machine.
● Reads and understands ALL Safety Decals on the machine.
● Clears the area of other persons.
● Learns and practices safe use of machine controls in a safe, clear area
before operating this machine on a job site.
It is your responsibility to observe pertinent laws and regulations and
follow Case Cor poration instructions on machine operation and
maintenance.
© 2003 Case, LLC 86986705

Issued February 2003
CASE and IH are registered trade marks of Case, LLC

CASE IH TECHNICAL MANUALS
Manuals are available from your Dealer for the operation,

service and repair of your machine. For prompt, convenient
service, contact your Dealer for assistance in obtaining the
manuals for your machine.
Your Dealer can expedite your order for operator’s manuals,

parts catalogs, service manuals and maintenance records.
Always give the Machine Name, Model and P.I.N. (product

identification number) or S.N. (serial number) of your
machine so your Dealer can provide the correct manuals for
your machine.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its

constituents are known to the State of California
to cause cancer, birth defects, and other
reproductive harm.
Battery posts, terminals and related accessories

contain lead and lead compounds. Wash
hands after handling.
NOTE: CNH America LLC reserves the right to make improvements in

design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.
SPX 4260 TROUBLESHOOTING MANUAL
TABLE OF CONTENTS
SECTION NO.
STANDARD TORQUE SPECIFICATIONS AND LOCTITE PRODUCT CHART . . . . . . . 1000
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1001
GENERAL INFORMATION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1003
MINOR ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4002
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4003
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5000
SPRAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000
A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000
CONTROLLER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8000
SPX 4260 REQUIRED AND RECOMMENDED TOOL LIST . . . . . . . . . . . . . . . . . . . . . . 9000
CASE IH APPLICATION EQUIPMENT

260 Highway 12 SE
Benson, MN 56215 U.S.A
© 2003 Case, LLC
SPX 4260 Troubleshooting Manual

Issued 2-03 Printed in U.S.A.
1000
Section 1000
STANDARD TORQUE SPECIFICATIONS
AND
LOCTITE PRODUCT CHART
Case IH Application Equipment

260 Highway 12 SE
Benson, MN 56215
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Standard Torque Specifications And Loctite Product Chart
1000 - 3
TABLE OF CONTENTS
TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Grade 5 Bolts, Nuts and Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Grade 8 Bolts, Nuts and Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Grade 8.8 Bolts, Nuts, and Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Grade 10.9 Bolts, Nuts and Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Grade 12.9 Bolts, Nuts and Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . .6

Split Flange Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Straight Threads with O-Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . .7

O-Ring Boss End Fitting or Lock Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
NOTE: Case, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any obliga-
tion to install them on units previously sold.

1000 - 4
TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques are not given. These torques apply to fasteners with both
UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if
special graphites, Molydisulfide greases, or other extreme pressure lubricants are used.
Grade 5 Bolts, Nuts and Studs Grade 8 Bolts, Nuts and Studs
Size Pound-Inches Newton Metres Size Pound-Inches Newton Metres

1/4 inch 108 to 132 12 to 15 1/4 inch 144 to 180 16 to 20
Size Pound-Feet Newton Metres Size Pound-Feet Newton Metres

1.0 inch 580 to 696 787 to 944 1.0 inch 900 to 1080 1220 to 1465
1-1/8 inch 800 to 880 1085 to 1193 1-1/8 inch 1280 to 1440 1736 to 1953

1000 - 5
TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not given.
These values apply to fasteners with coarse threads as received from supplier, plated or unplated or when
lubricated with engine oil. These values do not apply if graphite, Molydisulfide greases, or oil is used.
Grade 8.8 Bolts, Nuts, and Studs Grade 10.9 Bolts, Nuts and Studs
8.8 10.9
Size Pound-Inches Newton Metres Size Pound-Inches Newton

Metres
M4 24 to 36 3 to 4 M4 36 to 48 4 to 5
M5 60 to 72 7 to 8 M5 84 to 96 9 to 11
M6 96 to 108 11 to 12 M6 132 to 156 15 to 18
M8 228 to 276 26 to 31 M8 324 to 384 37 to 43
M10 456 to 540 52 to 61
Size Pound-Feet Newton
Metres
Size Pound-Feet Newton Metres M10 54 to 64 73 to 87
M12 66 to 79 90 to 107 M12 93 to 112 125 to 150
M14 106 to 127 144 to 172 M14 149 to 179 200 to 245
M16 160 to 200 217 to 271 M16 230 to 280 310 to 380
M20 320 to 380 434 to 515 M20 450 to 540 610 to 730
M24 500 to 600 675 to 815 M24 780 to 940 1050 to 1275
M30 920 to 1100 1250 to 1500 M30 1470 to 1770 2000 to 2400
M36 1600 to 1950 2175 to 2600 M36 2580 to 3090 3500 to 4200
Grade 12.9 Bolts, Nuts and Studs
12.9
Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

1000 - 6
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
37 Degree Flare Fitting Straight Threads with O-Ring

Tube OD Thread Pound- Newton Tube OD Thread Pound- Newton
Hose ID Size Inches Metres Hose ID Size Inches Metres
1/4 inch 7/16-20 72 to 144 8 to 16 1/4 inch 7/16-20 144 to 228 16 to 26

6.4mm 6.4mm
7.9 mm 7.9 mm
9.5 mm 9.5 mm
12.7 mm 12.7 mm
5/8 inch 7/8-14 300 to 696 34 to 79
15.9mm
Tube OD Thread Pound-Feet Newton
Hose ID Size Metres
Tube OD Thread Pound-Feet Newton 5/8 inch 7/8-14 58 to 92 79 to 124
Hose ID Size Metres 15.9mm
3/4 inch 1-1/16-12 40 to 80 54 to 108 3/4 inch 1-1/16-12 80 to 128 108 to 174
19.0mm 19.0mm
7/8 inch 1-3/16-12 60 to 100 81 to 135 7/8 inch 1-3/16-12 100 to 160 136 to 216
22.2 mm 22.2 mm
1.0 inch 1-5/16-12 75 to 117 102 to 158 1.0 inch 1-5/16-12 117 to 187 159 to 253
25.4 mm 25.4 mm
1-1/4 inch 1-5/8-12 125 to 165 169 to 223 1-1/4 inch 1-5/8-12 165 to 264 224 to 357
31.8 mm 31.8 mm
1-1/2 inch 1-7/8-12 210 to 250 285 to 338 1-1/2 inch 1-7/8-12 250 to 400 339 to 542
38.1 mm 38.1 mm
Split Flange Mounting Bolts

Size Pounds-Inches Newton Metres
5/16-18 180 to 240 20 to 27

3/8-16 240 to 300 27 to 34
7/16-14 420 to 540 47 to 61
Size Pounds-Inches Newton Metres
1/2-13 55 to 65 74 to 88
5/8-11 140 to 150 190 to 203

1000 - 7
TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS
O-Ring Face Seal End O-Ring Boss End Fitting or Lock Nut
Nom.
SAE Pound- Newton Pounds- Newton
Tube OD Thread Size Size
Dash Inches Metres Inches Metres
Size
-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27

6.4mm
-6 3/8 inch 11/16-16 216 to 240 24 to 27 9/16-18 300 to 360 34 to 41
9.5 mm
-8 1/2 inch 13/16-16 384 to 480 43 to 54 3/4-16 540 to 600 61 to 68
12.7 mm
-10 5/8 inch 1-14 552 to 672 62 to 76
15.9mm
Pounds- Newton
Size
Inches Metres
Nom. Tube OD Thread Size Pound-Feet Newton 7/8-14 60 to 65 81 to 88
SAE Hose ID Metres
Dash
Size
-12 3/4 inch 1-3/16-12 65 to 80 90 to 110 1-1/16-12 85 to 90 115 to 122
19.0mm
-14 7/8 inch 1-3/16-12 65 to 80 90 to 110 1-3/16-12 95 to 100 129 to 136
22.2 mm
-16 1.0 inch 1-7/16-12 92 to 105 125 to 140 1-5/16-12 115 to 125 156 to 169
25.4 mm
-20 1-1/4 inch 1-11/16-12 125 to 140 170 to 190 1-5/8-12 150 to 160 203 to 217
31.8 mm
-24 1-1/2 inch 2-12 150 to 180 200 to 254 1-7/8-12 190 to 200 258 to 271
38.1 mm
NOTE: Case, LLC reserves the right to make improvements in design or changes in specifications at any time
without incurring any obligation to install them on units previously sold.

1000 - 8
Working Fixture/Full Cure

Similar Gap Strength Temperature (Steel/Steel) Time
Product Color Products (In Inches) (Steel/Steel) Range-Farenheit Primer Description
N/A Form a Gasket (works with oil, fuel or
#3 Dark Brown 24 hr grease) Pliable

80 Yellow Fast N/A Weatherstrip Adhesive

123 Clear N/A N/A Parts Cleaner Fluid
220 Blue 290 0.003 57/143 in lbs -65 to +250 6 min/24 hrs 747 Wicking Threadlocker
221 Purple 222 0.005 75/44 in lbs -65 to +300 2 min/24 hrs 747 Low Strength Threadlocker
Low Strength Threadlocker
222 Purple 0.005 53/30 in lbs -65 to +300 20 min/24 hrs 764
(Small Screws)
225 Brown 222 0.010 45/25 in lbs -65 to +300 7 min/24 hrs 747 Low Strength Threadlocker
242 Blue 0.005 80/50 in lbs -65 to +300 10 min/24 hrs 764 Medium Strength Threadlocker
262 Red 271 0.005 160/190 in lbs -65 to +300 5 min/24 hrs 747 High Strength Threadlocker
270 Green 271 0.007 160/320 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
271 Red 262 0.007 160/320 in lbs -65 to +300 10 min/24 hrs 764 High Strength Threadlocker
272 Red 620 0.007 180/220 in lbs -65 to +450 30 min/24 hrs 764 High Temperature, High Strength
275 Green 277 0.010 210/300 in lbs -65 to +300 3 min/24 hrs 747 High Strength Threadlocker
277 Red 0.010 225/300 in lbs -65 to +300 60 min/24 hrs 764 High Strength Threadlocker
290 Green 0.003 85/350 in lbs -65 to +300 6 min/24 hrs 764 Wicking Threadlocker
*404 Clear 495 0.006 3200 psi -65 to +180 30 sec/24 hrs NA Instant Adhesive
*406 Clear 0.004 3200 psi -65 to +180 15 sec/24 hrs N/A Surface Insensitive Adhesive
*409 Clear 454 0.008 2500 psi -65 to +180 50 sec/24 hrs N/A Gel Instant Adhesive
*414 Clear 0.006 2500 psi -65 to +180 30 sec/24 hr N/A Instant Adhesive
*415 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Metals)
*416 Clear 454 0.010 2500 psi -65 to +180 50 sec/24 hrs N/A Gap Filling Instant Adhesive (Plastics)
*420 Clear 0.002 2500 psi -65 to +180 15 sec/24 hrs N/A Wicking Instant Adhesive
*422 Clear 454 0.020 2800 psi -65 to +180 60 sec/24 hrs N/A Gap Filling Instant Adhesive
*430 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
*445 White/Black 0.250 2000 psi -65 to +180 5 min/24 hrs N/A Fast Setting 2 Part Epoxy
Surface Insensitive Gen
*454 Clear 0.010 3200 psi -65 to +180 15 sec/24 hrs N/A
Instant Adhesive
*495 Clear 0.004 2500 psi -65 to +180 20 sec/24 hrs N/A General Purpose Instant Adhesive
*496 Clear 0.005 2500 psi -65 to +180 20 sec/24 hrs N/A Metal Bonding Adhesive
504 Brt Orange 515 0.030 750 psi -65 to +300 90 min/24 hrs None Rigid Gasket Eliminator
509 Light Blue 0.020 750 psi -65 to +320 6 hr/72 hrs 764 Flange Sealant
Standard Torque Specifications And Loctite Product Chart

510 Red 0.020 1000 psi -65 to +400 30 min/24 hrs 764 High Temperature, GAsket Eliminator
515 Purple 0.010 750 psi -65 to +300 1 hr/24 hrs 764 Gasket Eliminator 515
Rac 8-98902 * Products 404-496 (except for #445) are all instant adhesives (super glues) they differ mostly in viscosity Printed in U.S.A.
Working Fixture/Full Cure
Similar Gap Strength Temperature (Steel/Steel) Time
Product Color Products (In Inches) (Steel/Steel) Range-Farenheit Primer Description
518 Red 515 0.030 500psi -65 to +300 1hr/24 hrs 764 Gasket Eliminator 518 for Aluminum

542 Brown 569 N/A 132/92 in lbs -65 to +300 2 hr/24 hrs 747 Hydraulic Sealant
Low Strength Pneumatic/Hydraulic

545 Purple N/A 25/20 in lbs -65 to +300 4 hr/24 hrs 747
Sealant
549 Orange 504 0.020 2500 psi -65 to +300 2 hr/24 hrs 747 Instant Seal Plastic Gasket
554 Red 277 0.015 240/240 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Refrigerant Sealant
567 White 592 N/A 500 psi -65 to +400 4 hrs/24 hrs 764 Pipe Sealant for Stainless Steel
568 Orange 277 0.015 2500 psi -65 to +300 12 hrs/24 hrs 764 Plastic Gasket
569 Brown 545 0.010 40/25 in lbs -65 to +300 1 hr/24 hrs 764 Hydraulic Sealant
570 Brown 592 N/A 25/40 in lbs -65 to +300 6 hrs/72 hrs 764 Steam Sealant
571 Brown 592 0.015 40/20 in lbs -65 to +300 2 to 4 hrs/24 hrs 764 Pipe Sealant
572 White 578.575 N/A 80/27 in lbs -65 to +300 24 hrs/72 hrs None Gasketing
592 White 0.020 500 psi -65 to +400 4 hrs/72 hrs 736 Pipe Sealant with Teflon
593 Black 0.250 400 psi -95 to +400 30 min/24 hrs N/A RTV Silicone
601 Green 609 0.005 3000 psi -65 to +300 10 min/24 hrs 764 Current PIN #609
609 Green 0.005 3000 psi -65 to +300 10 min/24 hrs 764 General Purpose Retaining Compound
High Temperature Retaining
620 Green 640 0.015 3000 psi -65 to +450 30 min/24 hrs 747
Compound
635 Green 680 0.010 4000 psi -65 to +300 1 hr/24 hrs 747 High Strength Retaining Compound
638 Green 680 0.015 4100 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
640 Green 620 0.007 3000 psi -65 to +400 1 hr/24 hrs 747 High Temperature Retaining Compound
660 Silver 0.020 3000 psi -65 to +300 20 min/24 hrs 764 Quick Metal
675 Green 609 0.005 3000 psi -65 to +300 20 min/24 hrs 747 General Purpose Retaining Compound
680 Green 635 0.015 4000 psi -65 to +300 10 min/24 hrs 747 High Strength Retaining Compound
706 Clear 755 N/A N/A N/A N/A N/A Cleaning Solvent
707 Amber N/A N/A N/A N/A N/A Activaltor for Structural Adhesives
736 Amber N/A N/A N/A N/A N/A Primer NF
738 Amber N/A N/A N/A N/A N/A Depend Activator
747 Yellow N/A N/A N/A N/A N/A N/A Primer T
751 Clear N/A N/A N/A N/A N/A Activator for Structural Adhesives
755 Clear N/A N/A N/A N/A N/A Cleaning Solvent
764 Green N/A N/A N/A N/A N/A Primer N
767 Silver N/A N/A -65 to +1600 N/A N/A Anti-Seize Lubricant
1000 - 9
Standard Torque Specifications And Loctite Product Chart

Printed in U.S.A.
Rac 8-98901
1001
Section 1001
SAFETY

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Safety
1001 - 3
TABLE OF CONTENTS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1001 - 4
SAFETY
 WARNING: 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.
To prevent injury, always follow the Warning, Caution and Danger notes in this section and throughout the
manual.
Put the “Do Not Operate” tag shown below on the key for the key switch when servicing or repairing the
machine. 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.
DO NOT DO NOT REMOVE

OPERATE THIS TAB!
Reason See Other Side
Case Part No. Printed in

Signed by U.S.A.
 WARNING: Read the Operators Manual to familiarize yourself with the correct control
functions.
 WARNING: Operate the machine and equipment controls from the seat position only. Any
other method could result in serious injury.
 WARNING: This is a one person machine, no riders allowed.
 WARNING: Before starting engine, study Operators 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 Parts Manuals may be obtained from your equipment dealer.
 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 reflective clothing.

1001 - 5
 WARNING: When working in the area of the fan belt with the engine running, avoid loose
clothing if possible, and use extreme caution.
 WARNING: When doing checks and tests on the equipment hydraulics, follow the
procedures as they are written. DO NOT change the procedure.
 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.
 WARNING: Always wear heat protective gloves to prevent burning your hands when
handling heated parts.
 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.
 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.
 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).
 WARNING: Use suitable floor (service) jacks or chain hoist to raise wheels off the floor.
Always block machine in place with suitable safety stands.
 WARNING: When servicing or repairing the machine, keep the shop floor and operators
compartment and steps free of oil, water, grease, tools, etc. Use an oil absorbing material
and or shop clothes as required. Use safe practices at all times.
 WARNING: Some components of this machine are very heavy. Use suitable lifting
equipment or additional help as instructed in this Troubleshooting Manual.
 WARNING: Engine exhaust fumes can cause death. If it is necessary to start the engine in
an enclosed place, remove the exhaust fumes from the area with an exhaust pipe extension.
Open the door and get outside air into the area.

1001 - 6
 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.
 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 Operators Manual. Failure to follow these instructions can cause
serious injury or death.

1002
Section 1002
GENERAL INFORMATION AND SPECIFICATIONS

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. General Information And Specifications
1002 - 3
TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Needle Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Oil Seals, O-rings and Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

1002 - 4
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 groves can be removed with a hone or crocus cloth. Complete visual inspections 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 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 Operators Manual. Failures due to the use of non specified oils
and lubricants are not covered by warranty.

1002 - 5
SPECIFICATIONS
Item Specification
Engine CDC 6TA-830, 260 hp turbo charged and after cooled diesel
Drive Hydrostatic with full-time, 4-wheel drive. Infinitely variable shifting returns the wheel
motor to maximum torque each time the hydrostatic control lever is returned to neu-
tral. Allows maximum torque for each start.
Wheel Adjustment 120 in. - 152 in.
Suspension 4 wheel independent trailing arm with spring and shock standard. Active suspension
optional. 11 in. of travel.
Steering Hydraulic power steering. Orbital with master/slave rephasing cylinders.
Cab Air conditioner and heater with activated charcoal air filter
6 way adjustable suspension seat
2 speed windshield wiper
AM/FM stereo cassette system
Adjustable automotive type steering wheel
Full instrumentation
Tinted glass
Cab lighting
Hydraulic all wheel parking brakes with dynamic disc brakes on front wheels with
brake pedal in cab.
Travel Speed 30 mph / 48 kph
Fuel Tank 140 gallons (399 liters) diesel only
Dimensions Dry weight 24,000 lbs (10,896 kg)
(380/85 R46 tires, 90’ boom)
Tank size 1200 gal (4560 liters) SS
Nozzle spacing 20 in. preset others available
Overall length 336 in. (28 ft. / 8.6 m)
Overall width 138 in. (11 ft. 6 in. / 3.5 m) (retracted)
170 in. (14 ft. 2 in. / 4.4 m) (extended)
Overall height 144 in. (12 ft. / 3.65 m)
Wheel base 150 in. (12 ft. 6 in. / 3.8 m)
Ground clearance 54 in. / 137 cm (tank empty)
52 in. / 132 cm (tank full)
Tire Sizes 380/85 R46
650/65 R38
320/90 R46 (optional)
Turning Radius Axles in - 20 ft. 6 in. / 6.25 m
Axles out - 21 ft. 4 in. / 6.5 m
Boom Boom length 60’-90’
60’-80’ (optional)
Boom tip breakaway 5.5 ft. / 1.68 m

1002 - 6
Item Specification
Sprayer Control Raven, Mid-Tech or Optional Dickey-john Land Manager
Product Pump Centrifugal pump, hydraulic motor driven with electric cab control
Foam Marker 60 gal / 152 liters
Rinse Tank 70 gal / 266 liters
Hydraulic Tank 25 gal / 94.6 liters
Capacity
Coolant Capacity Radiator 7.2 gal / 27.3 liters
Entire coolant system 11.2 gal / 42.4 liters
Chemical Inductor Optional
Paint Long lasting, durable polyurethane

1003
Section 1003
MAINTENANCE

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Maintenence
1003 - 3
TABLE OF CONTENTS
LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Proper Disposal Of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
LUBRICANTS AND CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Gear Increaser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Engine Oil Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Oil Viscosity/Temperature Usage Recommendation . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Cleaning the Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommended Break-In Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommended Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
10 HOURS OR DAILY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Liquid Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cab Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Trailing Arm Pivot Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Checking the Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Indicators, Switches and Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Boom Cylinders and Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Boom Cylinders and Joints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Strut and Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1003 - 4
50 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Filter Water Drain Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel Tank Water Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Battery Cables and Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Loose Bolts and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Compressor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hub Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Radiator and Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
250 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Engine Oil Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Engine Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Batteries Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hydraulic Hoses and Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Air Intake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Fuel Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Fuel System Air Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
In-line Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Changing Hydraulic Oil and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hydraulic System Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spray System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gear Increaser on Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Hub Lubricant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Coolant Filter/Conditioner and Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Cab Recirculation Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cab Outside Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1200 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2100 HOUR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Coolant Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
AS REQUIRED MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Direct Drive Air Compressor / Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Thermostat Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Booms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hydraulic Pump or Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Foam Marker (Turbo) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wear Pads on Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1003 - 5
LUBRICATION AND MAINTENANCE

Proper Disposal Of Materials
Before servicing this machine and before you dispose of old fluids, lubricants, and filters always remember the
environment.
Do not pour oil or fluids in the ground, down drains or into containers that can leak.
Dispose of all old fluids, lubricants and filters in accordance with local regulations.
Check with your local environment recycling center or your dealer for correct information.
PLASTIC AND RESIN PARTS

DO NOT use gasoline, paraffin, paint thinner, naptha, etc., when cleaning plastic, e.g.; console, instrument
cluster, monitors and gauges etc.
Use ONLY water, mild soap and a soft cloth when you clean these parts. Using gasoline, paraffin, paint thinner
etc., will cause discoloration, cracking or deformation of the part being cleaned.
 WARNING: To prevent eye injury, always wear goggles or full face protection before using
compressed air or high pressure washers.
LUBRICANTS AND CAPACITIES

Engine
Oil Type............................................................................................................ Case No.1, See recommendation
Oil Capacity - Without Filter Change ........................................................................................... 19 Liters (5 gal)
Oil Capacity - With Filter Change .......................................................................................... 21 Liters (5-1/2 gal)
NOTE: The oil level dipstick is only a guide, when you fill the engine crankcase with oil always measure the
amount of oil you put in.
Cooling System
Coolant Mix...............................................................................Solution of 50% Water and 50% Ethylene Glycol
System Coolant Capacity ...........................................................................................42.4 Liters (11.2 U.S. Gal)
Radiator Capacity ..........................................................................................................27.3 Liters (7.2 U.S. Gal)
Fuel Tank
Fuel Type ................................................................................................................................... No. 2 Diesel Fuel
Fuel Tank Capacity .......................................................................................................530 Liters (140 U.S. Gal)
Hydraulic System
Oil Type......................................................................................................................... Case HY-TRAN ULTRA®
Tank Capacity .................................................................................................................94.6 Liters (25 U.S. Gal)
Gear Increaser
Oil Type............................................................................................................................................. 80W90 GL-5
Capacity.................................................................................................................................................. 7.5 Pints

1003 - 6
ENGINE LUBRICATION
Engine Oil Selection
Case No. 1 Multi-Viscosity Engine Oil is recommended
for use in your Case engine. Case Engine Oil will
lubricate your engine correctly under all operating
conditions.
If Case No. 1 Multi-Viscosity Engine Oil is not available,
use only oil meeting API engine oil service category CF-
4 or CG-4.
NOTE: Do not put Performance Additives or other oil

additive products in the engine oil. The oil change
intervals given in this manual are according to tests with
Case lubricants.
RD97F135
Oil Viscosity/Temperature Usage Recommendation
Fahrenheit
-40 -22 -4 14 32 50 68 86 104 122
Tropic SAE 20W-50
All
Seasons * SAE 15W-40
* Case No. 1 15W-40
* SAE 10W-30
Winter
* Case No. 1 10W-30
* SAE 5W-30 Arctic
-40 -30 -20 -10 0 10 20 30 40 50

Celsius
* Use of an engine oil heater, or an engine coolant heater, is required in these areas.

1003 - 7
COOLANT SOLUTIONS
Your sprayer cooling system is equipped with an ethylene glycol coolant solution that has a high boiling point.
IMPORTANT:Change the coolant solution at the change interval recommended. The heat generated by the
diesel engine causes a natural change in the inhibitors in the coolant which results in loss of corrosion
protection. The loss of the inhibitors may cause water pump cavitation and cylinder block erosion.
Install only ethylene glycol coolant solution in the cooling system. Use a good quality, high boiling point,
ethylene glycol that does not have any additives to stop leaks. The silicate content must not exceed 0.1
percent. (Use Case Coolant part number 331- 511).
Do not install any rust inhibitors that are not approved. It is possible that the rust inhibitors and ethylene glycol
will not mix and work against each other to decrease corrosion protection, form deposits in the cooling system
and cause damage to the cooling system and the radiator.
Do not use a low boiling point, alcohol type coolant solution. Because the boiling point of alcohol is below the
sprayer minimum operating temperature, loss of coolant from evaporation can be excessive.
IMPORTANT:Always have a minimum of 50 percent ethylene glycol coolant in the cooling system at all times
and at all ambient temperature ranges. Do not install more than 50 percent ethylene glycol in the cooling
system unless the ambient air temperature will be less than -34°F (-37°C). More than 50 percent ethylene
glycol decreases heat transfer and will cause the engine surface temperature to be more than normal.
Prepare the coolant solution as follows:
1. Mix 1 pint (0.45 L) Case water conditioner (part # B91245) with 3 gallons (11.4 L) of clean water.
2. Mix this water solution with 3 gallons (11.4 L) of ethylene glycol coolant.
3. Mix remaining coolant 50% anti-freeze to 50% clean water ratio.
HYDRAULIC SYSTEM
Hydraulic Oil
 WARNING: Extreme caution must be used when working adjacent to and with high pressure
hydraulic oil lines. If any oil is injected into the skin, it is absolutely essential that the injured person
seek immediate medical care from a facility that is familiar with this type of injury or permanent injury
may result.
The use of approved oil in the hydraulic system is essential for satisfactory system operation. Keep the
hydraulic oil in the original closed containers. Clean the top of container before opening and pouring. Use a
clean funnel with built in strainer and use extreme care to keep dirt out of the system.
The hydraulic system, i.e. tank, lines, wheel motors, hydrostatic pumps on your vehicle requires approximately
25 gallons of oil.
Changing the Hydraulic Oil

• As specified in Periodic Maintenance section of this manual (Recommended After Every 500 Hours),
• Whenever contamination is suspected or
• Once a year when the vehicle is put in storage.
IMPORTANT: In any instance when the level of oil in the hydraulic oil tank falls below the safe operating level,
a hydraulic hose fails, or a hydraulic leak develops, IMMEDIATELY shut off the engine and do not restart until
oil levels are restored to operating levels.

1003 - 8
NOTE: If the natural color of the fluid has become black or milky, it is possible that an overheating or water
contaminant problem exists. If either of these situations exist determine the cause and make the necessary
repairs then change the oil and filters.
Hydraulic Oil Specifications

Use only hydraulic oils specified. (Use of unspecified oil will void your warranty.)
Oil Type ......................................................................................................................... Case HY-TRAN ULTRA®

Tank Capacity................................................................................................................. 94.6 Liters (25 U.S. Gal)
NOTE: It is best not to mix hydraulic oil from different manufacturers. It is far better to mix however, than run
your vehicle with low level of oil. Mixed oil should be completely changed as soon as possible using the
recommended oils specified above. Your applicator came from the factory filled with oil as marked on tag on
filler neck or ignition key.
Hydraulic Oil Filters

IMPORTANT: Filtration of hydraulic oil is critical to proper lubrication. Use only filters meeting performance
specifications. Use of improper filters may lead to premature hydraulic failure and will void your warranty.
This vehicle has a in-tank return filter (Item 1) that is a 6

micron Beta=75 (absolute) which is located on top of the
hydraulic tank and two hydrostatic charge filters (Item 2)
which are a 5 micron Beta=75 (absolute) located on either
side of the hydraulic pumps.
Change the hydraulic oil filters according to the following: 1
• Change the hydraulic oil filters as specified in the

Periodic Maintenance section.
• Change the hydraulic oil filters when oil is changed
seasonally.
• Change the in-tank return filter (Item 1) element when
the visual indicator shows red at normal operating
temperature at full engine rpm. (The hydraulic
reservoir is pressurized; release pressure (Item 3) 3
before opening the filter housing.)
P0001291
• Change the hydrostatic charge system filters (Item 2),

release tank pressure before opening the filter
housing.
• Change the hydraulic oil filters, if hydraulic oil is being
changed, when contamination is suspected.
2
P0002024

1003 - 9
Cleaning the Hydraulic System
IMPORTANT: All hydraulic fluid is dirty! Anytime the hydraulic system(s) is opened up for repairs and/or
anytime fluid is changed or added, it must be assumed that contaminants are being introduced to the system.
Cleanliness cannot be overemphasized. Changing the oil filter and oil at the proper intervals is necessary to
maintain quality and a reliable system.
New oil purchased either in bulk or in sealed containers does not meet the cleanliness standards required to
insure satisfactory operation and prolonged life of hydrostatic components. Therefore, it is recommended that
new oil be pumped into the reservoir through the return filter, center fitting.
The vehicle's filtration system is a very effective one, and can be utilized to clean the hydraulic oil after the
hydraulic system has been opened up for repair or after adding or changing the hydraulic oil. This will minimize
the risk of contamination damage. Run the machine for at least 1 hour under light load, after changing the
hydraulic fluid.
IMPORTANT: It is of utmost importance when working on any hydraulic system to keep the components and
surrounding area being serviced as clean as possible. Pressure wash all mud, grease, oil, and dirt off the area
to be opened up and serviced. Before loosening and removing hydraulic fittings and hoses, spray the
immediate area around the fittings with a pressure washer. If an aerosol degreaser such as brake cleaner or
carburetor cleaner are used, (these are flammable fluids) do not smoke and only use in a well ventilated area.
Have threaded plugs and/or caps of the proper size in hand to install immediately. Do not leave hoses or
hydraulic components exposed.
NOTE: Only use hydraulic oil filters that meet or exceed the Micron and Beta Ratio specified by Case IH
Application Equipment. Filters used on Case IH Application Equipment machines that fall below the
specifications may void the hydraulic system warranty depending on individual circumstances. It is highly
recommended to use Case IH Application Equipment supplied filters as we continually monitor our filter
manufacturers for quality.
1. Replace the in-tank filter and the two hydrostatic charge filters.
2. After new filters are installed, start engine and run at 1800 rpm with vehicle in neutral. Cycle all cylinders 5
times and turn the steering wheel lock to lock. Run the product pump for 5 minutes if repair was done to its
circuit (be sure there is water in the liquid tank). This will move any contamination debris to the tank.
3. Allow engine to run at 1800 rpm with the vehicle in neutral for 30 minutes to warm the system and clean
the oil in the tank.

1003 - 10
MAINTENANCE SCHEDULE
Recommended Break-In Maintenance
The following maintenance is only recommended as a first time required maintenance. Regularly scheduled
maintenance is still required in addition to the break-in maintenance.
FREQUENCY IN HOURS
CHANGE
TORQUE
GREASE
CHECK
CLEAN
DRAIN
SERVICE POINTS
FILL
Hub Lubricant 50 50
A/C Compressor Belt 50
Gear Increaser Lubricant 100 100
Recommended Maintenance Schedule

The following maintenance schedule is recommended at every time interval stated below.
FREQUENCY IN HOURS
CHANGE
TORQUE
GREASE
CHECK
CLEAN
SERVICE POINTS DRAIN
FILL
Machine Care 10
Liquid Tank 10
Cab 10
Trailing Arm Pivot Area 10
Fuel Tank 10
Engine Oil Level 10
Hydraulic Oil Level 10
Coolant Level 10
Brake Operation 10
Indicators, Switches, Lights 10
Safety Equipment 10
Wheel Nuts 10
Boom Cylinders and Joints 10
Boom Parallel Linkage 10
Strut and Axle Assembly (Hours vary see recom- 10
mendation)
Fuel Filter Water Drain 50
Fuel Tank Water Drain 50
Battery Connections 50
Hub Lubricant Level 50
Loose Bolts or Parts 50

1003 - 11
FREQUENCY IN HOURS
CHANGE
TORQUE
GREASE
CHECK
CLEAN
DRAIN
SERVICE POINTS
FILL
Tire Pressure 50
Engine Air Filter 50
Radiator and Coolers 50
Battery Top 250
Hydraulic Hoses and Wiring Connections 250
Air Intake Hoses 250
A/C Compressor Belt 250
Engine Coolant Mixture Level 250
Engine Oil 250 250
Engine Oil Filter 250
Gear Increaser Lubricant 500 500
Hub Lubricant 500 500
Hydraulic Tank Fluid 500 500
Hydraulic Return Filter 500
Coolant Filter /Conditioner / Hoses 500
Hydraulic System Breather 500
Fuel Filter 500
In-line Fuel Filter 500
Fuel System Air Removal 500
Spray System 500
Cab Recirculation Screen 900
Cab Air Filter 900
Engine Air Filter 1200
(Primary/Secondary)
Coolant 2100 2100
NOTE: Be sure to completely read through the Maintenance section. There are important warnings and notes
that apply to the items above.

1003 - 12
10 HOURS OR DAILY
Machine Maintenance
 WARNING: Fertilizer is very corrosive and will oxidize steel over a period of time. This weakens
steel parts and can cause possible safety hazards. Periodically check safety shields and structural
members for corrosion. Replace or repair anything that could cause a potential safety hazard.
Regular daily cleaning will contribute more to the life of the vehicle than any other single maintenance effort.
Any accumulation of chemical or fertilizer will cause rapid corrosion. High pressure water is one of the most
effective cleaning agents.
Liquid Tank
 WARNING: Follow chemical manufacturers and State and Federal EPA instructions for proper
handling, transportation and disposal of fertilizer and chemical residue.
Wash the machine and clean the liquid tank inside and
out after each days use.
• Check tank for signs of wear in places where the tank

has been welded. Check the tank mounts to insure
the tank is secure to the frame.
• Check the fittings for broken parts, cracks, wear
marks or other signs of potential leaks.
• Check fitting gaskets for deterioration. They have a
shorter life than the tank itself. Look for discoloration,
bulges, or checking. All of these symptoms could indi-
cate potential failure.
• Inspect the valves and/or pumps that are connected
P0001288
to the tank. Also inspect the hoses and connections
for any signs of wear.
Cab Maintenance
• Floor areas should be kept clean from foreign material. Periodic sweeping and/or vacuuming of the floor or
coverings is recommended.
• Headliners and inside wall cowlings should be periodically wiped clean with a cloth, vacuumed or other-
wise cleaned.
• It is recommended that the exterior of your vehicle that has been exposed to pesticides during field applica-
tions should be washed down to reduce the potential of operators coming in contact with the pesticides.
• Disposition of wash water containing hazardous concentrations of active/inert ingredients should be han-
dled according to published regulations or directives.

1003 - 13
Trailing Arm Pivot Area
Clean the trailing arm pivot area every 10 hours. Be sure

suspension, wheel motor and spring are free from mud.
Fuel Tank
Fill the fuel tank at the end of each days use, to prevent
condensation from forming in the tanks. Tank capacity is
140 gallons.
Use a good grade of diesel fuel which complies with

P0001307
specification SAE/ASTM EN 590 or equivalent in your
Case diesel engine. The use of a low grade fuel will result
in loss of engine power and high fuel consumption.
If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank.
Many engine problems are caused by water in the fuel. Keep the fuel storage tank outside and keep the fuel as
cool as possible. Remove water from the fuel storage tank at regular intervals.
 WARNING: Be careful when filling fuel tanks. Never fill fuel tank when engine is hot or running. Do
not allow smoking or open flame near machine while filling fuel tanks.
NOTE: Different grades of diesel fuel are required for summer and winter operations. See your fuel supplier
for winter fuel requirements in your area.
Fuel Conditioner
Diesel Fuel Conditioner is available from your service representative. Instructions for the use of the fuel
conditioner is on the container.
The use of Diesel Fuel Conditioner will:
• Clean fuel injectors, valves and manifolds for increase service life.
• Disperse insoluble gummy deposits that can form in the fuel system.
• Separate moisture from the fuel.
• Stabilize fuel in storage.
Engine Oil Level
To check the engine oil level:
1. Put the sprayer on level ground and stop the

engine. 1
2. Wait for 15 minutes for the oil to settle before check- 2
ing the oil level.
3. Make sure the dipstick (Item 1) is pushed com-
pletely down before checking the oil level.
4. If the oil level is below the ADD mark, add oil,
through the filler tube (Item 2), to raise the oil level P0002485
to the FULL mark. DO NOT raise the oil level above
the FULL mark.

1003 - 14
Checking Hydraulic Oil Level
Check the hydraulic oil level daily. When fluid is not visible on the bottom of the sight gauge, add hydraulic fluid
to the top of the sight gauge. Do not overfill the hydraulic tank.
IMPORTANT:When the oil is not visible on the bottom of sight gauge, the oil level is low. Add oil until it is visible
on the top of sight gauge. Start engine and run, in neutral, at a minimum engine rpm of 1800 for a minimum of
20 minutes to filter and warm the oil prior to any operation.
Checking the Coolant Level

Check the coolant level in the coolant recovery tank every 10 hours of operation or daily. DO NOT REMOVE
THE RADIATOR CAP.
Check the coolant when the coolant is cold and the engine is stopped.
The coolant level must be within the normal cold range marks on the tank.
If the level is below the ADD mark, fill the tank to the top mark of the normal cold range with the coolant mixture
of 50% antifreeze to 50% water.
Brake Operation
Check dynamic brake for proper operation every 10

hours of operation and each time the machine is
started.
Depressing the brake pedal will deactivate the propel

handle and stop the machine. The pedal should feel
firm. Return the propel handle to neutral to regain
control handle function.
See your documentation packet for information on

servicing the disc brakes located on the front wheel DCP01787
hubs.
Indicators, Switches and Lights

Check all indicators, switches and lights for correct operation after every 10 hours of operation. Replace any
parts that are not working correctly.
Wheels and Tires
 WARNING: Always stop the engine and engage the parking brake before working on the machine.
 WARNING: Follow tire and wheel manufacturers instructions when mounting a tire on a wheel or
rim. Failure to do so could produce an explosion that may result in serious injury or death. Do not
attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Have it done by a qualified tire repair service. Do not exceed the inflation pressure recommended by
the tire manufacturer.

1003 - 15
 WARNING: Explosive separation of the tire and/or rim parts can cause injury or death. When tire
service is necessary, have a qualified tire mechanic service the tires.
 WARNING: Use a clip on air chuck, extension hose with gauge and stand away from the tire while
inflating to prevent the possibility of personal injury due to a tire and rim separation, etc.
 WARNING: A tire can explode during inflation and cause serious injury or death. Never increase air
pressure beyond 35 PSI (2.4 bar) to seat the bead on the rim. Replace a tire if it has a defect.
Replace a wheel rim which has cracks, wear or severe rust. Make sure that all the air is removed
from a tire before removing the tire from the rim. Never use force on an inflated or partially inflated
tire. Make sure the tire is correctly seated before inflating to recommended operating pressure.
 WARNING: DO NOT weld to a wheel or rim until the tire is completely removed. Inflated tires can
generate a gas mixture with the air that can be ignited by high temperatures from welding procedures
performed on the wheel or rim. This condition can exist whether tires are inflated or deflated.
Removing air or loosening the tire on the rim (breaking the bead) will NOT eliminate the hazard. Tire
MUST be completely removed from the rim prior to welding.
 WARNING: Should you experience loss of air due to a crack in the rim, contact your Case IH
distributor or dealer to resolve the matter. DO NOT continue operation by installing a tube. DO NOT
attempt to weld repair the rim. Continued use could result in complete wheel failure.
Tire Inflation
380/85R46 Dyna Torque Radial 146D

Loads and inflations at 30mph/40kph
PSI 43.5 46.4 49.3 52.2 53 max

BAR 3 3.2 3.4 3.6 3.7
LBS 7850 8050 8250 8550 8700
KG 3550 3650 3750 3875 3950
320/90R46 DT800 148A8

PSI 37.7 40.6 43.5 46.4 49.3 52.2 55.1 58 max

BAR 2.6 2.8 3 3.2 3.4 3.6 3.8 4
LBS 5840 6150 6400 6600 6800 6950 7150 7400
KG 2650 2800 2900 3000 3070 3150 3250 3350
(148A8)
650/65R38 DT820 157A8

PSI 8.7 11.6 14.5 17.5 20.3 23.2 max

BAR 0.6 0.8 1 1.2 1.4 1.6
LBS 5080 5840 6800 7600 8250 9100
KG 2300 2650 3075 3450 3750 4125
(157A8)
MAXIMUM SPEED 10 MPH 15 MPH 20 MPH 25 MPH 30 MPH

1003 - 16
% CHANGE IN LOADS IN +34% +11% +7% NONE NONE

ABOVE TABLE (except hillside Combines) (except hillside Combines)
 WARNING: Follow tire manufacturers recommendations for highway speeds and loading of tires.
Failure to do so may result in injury
Toe In
Adjust front wheel steering cylinders for 1/4”-1/2” less at front of tire
than at rear (center of hub).
Steering arm assembly must be straight ahead (centered) on front

axle.
Torque Requirements: Check wheel nuts daily.

POOO2018
NOTE: Be careful when tightening the wheel nuts. Do Not Over
Torque.
Safety Equipment
Check all safety equipment such as hazard lights, decals, seat belt, etc. for proper operation and placement
after every 10 hours of operation.
Seat Belt Inspection and Maintenance
 WARNING: Securely fasten your seat belt. The seat belt can insure your safety if it is used and
maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a
twisted condition or pinched between the seat structural members.
• Keep the belt away from sharp edges and items that can cause damage.
• From time to time, check belt, buckles and mounting bolts for damage.
• Replace all parts that are worn or damaged.
• Replace a belt that has cuts that can weaken the belt.
• Check that the bolts are tight on the seat bracket.
• Keep seat belt clean and dry.
• Clean belt with a soap solution and warm water. Do not use bleach or dye on the belt because this can
make the belt weak.

1003 - 17
Boom Cylinders and Joints
Grease the eight grease fittings per side daily. Use a #2 general purpose lithium based grease.
1615
1614
Boom Parallel Linkage
P0002482
P0002483
Grease the four grease fittings per side daily. Use a #2 general purpose lithium based grease.

1003 - 18
Strut and Axle Assembly
Grease the five grease fittings per wheel as indicated.

Use a #2 general purpose lithium based grease.
50 Hours
50 Hours
1613
50 HOUR MAINTENANCE
Fuel Filter Water Drain Plug

The drain plug (Item 1) is located on the bottom of the
primary fuel filter. Every 50 hours of operation, loosen
the plug to let any water or sediment drain from the
filter. Tighten the plug once the water has drained.
DCP01767

1003 - 19
Fuel Tank Water Drain Plug
The drain plug (Item 1) is located under the fuel tank.
Remove the plug to remove any water or sediment from
the fuel tank. After the water is removed, replace the
plug.
P0002037
Battery Cables and Terminals

The battery terminals must be kept clean and tight. A
good method to clean the terminals is to use Battery
Saver, Case Part Number M20376 according to
instructions on the container. This cleaner needs no
water. If Case Battery Saver is not available, remove all
corrosion with a wire brush, then wash with a weak
solution of baking soda or ammonia. Put some
petroleum jelly or light grease on terminals to prevent
more corrosion.
NOTE: Apply Case Battery Saver or Urethane Seal

Coat to the cable terminals to prevent corrosion.
DO NOT use grease.
P0002651
Loose Bolts and Parts

Do a through check every 50 hours of use to the machine making sure there are no loose bolts or parts. If any
of the parts or bolts are loose retighten to torque specifications.
Compressor Belt
NOTE: Check the belt tension after the first 50 hours and then use regular check interval.
Measure the compressor belt for correct tension using a belt tension gauge. Check the belt to the following
specifications:
New belt 95 to 115 lbs (422 to 516 Nm)

Used belt 90 to 110 lbs (400 to 489 Nm)
NOTE: Adjust new belts to the used belt specification after a 10 minute run-in.

1003 - 20
Compressor Belt Adjustment
To adjust the belt tension, loosen the compressor adjusting
bolts and pivot bolts. Push the compressor up until the
correct tension for the belt is reached. Tighten the 1
compressor adjusting bolts and pivot bolt.
1. A/C Compressor
2. A/C Compressor Belt
3. Engine Fan Belt
4. Fan 2
Compressor Belt Replacement
1. Loosen the adjusting bolts and pivot bolt for the
compressor. Push the compressor down to loosen the
belt.
2. Remove the compressor drive belt. Install a new drive 4
belt.
3. Measure the compressor belt for correct tension using
a belt gauge. Belt tension must be 95 to 115 lbs (422 to
516 Nm) for a new belt. After ten minutes run-in time on 3
the new belt, adjust tension for 90 to 110 lbs (400 to
489 Nm).
4. Push compressor up until correct tension for the belt is
reached. Tighten the adjusting bolt and pivot bolt.
Hub Lubricant
DCP01773
The initial OEM lubricant fill for all planetary hubs on this
vehicle is 85W140 GL-5 gear lube. It is extremely important
that the hub lubricant be changed at 50 hours of operation (break-in period) for all new hubs or any time new
hubs or gears are installed into a hub as repair parts. The importance of this initial break-in lubricant change
cannot be overemphasized. The recommended lubricant for all hubs is 85W90 GL-5 gear lube or 85W140 in
warmer climates.
Check oil level with plug
The vehicle is propelled with four (4) hubs giving it very 1 in. below center of hub.
good traction on all terrains. Each hub should be
checked regularly for the proper amount of lubrication.
To check the hub lubricant:

1 in.
1. Rotate the wheel so that the check plug is 1 in.
below center point of the wheel as shown. Plug
2. Remove the check plug using a 1/4” Allen head
wrench. If oil is at this level, it's at the correct oper-
ating level and the plug should be inserted. If oil is DCP01874
below hole, add 85W90 GL-5 gear lube or 85W140
in warmer climates until oil just begins to run out.
3. Insert check plug.
Each hub with integral brake has a total oil capacity of 58 oz. All four hubs have integral brakes. The oil level in
the hubs should be checked every 50 hours and changed every 500 hours under normal operating conditions.
If the hub is “overfull”, drain to proper level. Recheck two hours later. If it is “overfull” again it is likely the wheel
motor has a shaft seal that is leaking hydraulic oil into the hub. In this case, call your local service
representative.
NOTE: Under high speed use (driving down the road) the planetary gears create heat and pressure in the hub.
This pressure is released around the seal and some oil weeping may occur.

1003 - 21
Radiator and Coolers
To clean the radiator and coolers, first remove the grill
screen which will expose the a/c condenser. Remove
the two bolts on the a/c condenser and swing out to
expose the oil cooler.
Then remove the oil coolers two bolts and swing out to
expose the radiator.
Clean dirt and dust from all grill screens, a/c condenser,
oil cooler and the radiator. Blow with compressed air or
water.
NOTE: Be careful not to bend or damage the fins

during cleaning.
P0001293
250 HOUR MAINTENANCE
Engine Oil Change

To change the engine oil, put the sprayer on level ground and stop the engine. Change the engine oil as
follows:
NOTE: For best results change the oil while the engine is still warm from operation. Use caution when
removing plug and draining oil.
1. Remove the oil pan remote drain plug (Item 1).

2. Remove safety cap on the bottom of the drain hose,
open the drain gate valve on the bottom of the oil
pan, and drain the oil into appropriate container.
3. Close drain gate valve on the bottom of the oil pan
and install safety cap on the bottom end of the drain
hose.
4. See Engine Oil Filter instructions for filter change.
5. Install the remote drain plug (Item 1). 1
6. Put the correct type and amount of new oil into the
engine oil fill. Refer to engine oil specifications and
capacities in the front of this section.
7. Operate the engine for five minutes at 1000 rpm. P0002477
Check for oil leaks at the filter base and drain plug.
8. Stop the engine. Wait approximately five minutes for the oil to return to the oil pan. Check the oil level on
the dipstick and add oil if needed.

1003 - 22
Engine Oil Filter
IMPORTANT: Change the oil filter at the recommended time interval. Your service representative has
approved filters. Do not use other type filters.
Change the engine oil filter (Item 1) as follows:
1. Drain the oil from the engine and reinstall the drain
plug.
2. Turn the oil filter counterclockwise to remove. Use a
strap wrench, if necessary.
3. Apply clean oil to the gasket on the new filter. 1
4. Install the filter. Turn the filter clockwise until the gas-
ket comes in contact with the filter head. Tighten the
filter an additional one half turn by hand.
5. Loosen the filter approximately one turn. Turn the fil-
Dcp03915
ter clockwise again until the gasket comes in contact
with the filter head. Tighten the filter an additional 1/2 to 3/4 of a turn by hand.
IMPORTANT: DO NOT use a filter wrench to install the oil filter. If the filter is too tight you can damage the
gasket and filter.
6. Install new oil in the engine.
Batteries Level Check

Check the water level in each cell. Remove cover plate carefully. Water must be added before the top of the
separators show. Do not over fill.
Add distilled water to the batteries. When water is added at ambient temperatures below 32×F (0×C) the
batteries must have a charge immediately to mix the water and electrolyte. Freezing of the water will occur if
the water is not mixed with the electrolyte, because the water will stay at the top.
 WARNING: BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid
contact with skin, eyes or clothing. Antidote: EXTERNAL - flush with water. INTERNAL - Drink large
quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetable oil. Call physician
immediately. EYES - Flush with water for 15 minutes and get prompt medical attention. BATTERIES
PRODUCE EXPLOSIVE GASES. Keep sparks, flame and cigarettes away. Ventilate when charging
or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH
OF CHILDREN.
 WARNING: Battery posts, terminals, and related accessories contain lead and lead are known to
the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after
handling.

1003 - 23
Keep your batteries in good operating condition as follows:
• Add distilled water as needed to keep separators under water.

• Keep the batteries with a full charge as shown on a hydrometer.
• Keep the batteries clean and dry. Make sure the batteries are fastened in position.
• If the batteries will not keep a charge, install new batteries that are 12VDC 950 CCA low maintenance.
• Before you add water, check each cell with a hydrometer. The specific gravity in each cell must have full
charge.
• When using a battery charger, charge at the lowest rate possible to reduce gas formation. DO NOT charge
a frozen battery, it can explode.
NOTE: The full charge specific gravity will be shown on the battery most of the time. Cold temperatures of
approximately 0°F (-17.7°C) will cause freezing of a battery with a specific gravity of 1.175.
NOTE: Electrolyte level should be 0.125 to 0.25 inch (3.2 to 6.4 mm) below vent well.
Hydraulic Hoses and Electrical Wiring

Every 250 hours check all hydraulic fittings and hoses for leaks or wear. Check all electrical connections and
connectors. Replace any parts that may look damaged.
 WARNING: Extreme caution must be used when working adjacent to and with high pressure
hydraulic oil lines. If any oil is injected into the skin, it is absolutely essential that the injured person
seek immediate medical care from a facility that is familiar with this type of injury or permanent injury
may result.
Engine Air Intake Hoses

Check to make sure all hoses and clamps are tight on the air induction system. Replace any hoses that are
damaged.
Fuel Filter Replacement

1. Clean the filter head, filter(s) and engine area next
to the filter(s).
2. Open the drain plug on the primary filter (Item 1)
and drain all fuel.
3. Use a clamp wrench and turn the primary filter and
the secondary filter (Item 2) counterclockwise to
remove.
4. Install new gaskets on the primary and on second-
2
ary mounting studs.
1
5. Apply clean oil or grease to the gasket(s) on the
new filter(s).
NOTE: Do not fill the new fuel filter(s) with fuel before
installation.
DCP01767
6. Turn filter(s) clockwise until filter gasket comes in
contact with filter head. Use your hand to tighten 1/2 of a turn. To get correct seal, loosen filter(s) and again
tighten 1/2 to 3/4 of a turn after gasket comes in contact with filter head. When the filter(s) are too tight, you
can cause damage to the gaskets and filters.
7. Fill the fuel tank and remove air from the fuel system. See Fuel System Air Removal.

1003 - 24
 WARNING: Be careful when filling fuel tanks. Never fill fuel tank when engine is hot or running. Do
not allow smoking or open flame near machine while filling fuel tanks.
Fuel System Air Removal

Air must be removed from the fuel system. Air can enter the fuel system under the following conditions:
• The fuel tank has no fuel.

• Fuel system parts are removed for service or repairs.
• The sprayer is in storage for a long period of time.
NOTE: If the sprayer has no fuel, it is possible to put fuel in the tank and start the engine without doing the air
removal procedure. However, a small amount of air can be in the filters and injection pump. Air in the system
will cause loss of power and engine stall when a load is applied.
1. Loosen the air removal screw located at the outlet

fitting from the fuel filter housing.
2. Operate the hand primer pump (Item 1) to fill the
fuel filters with fuel. Tighten the air removal screw
when clear fuel with no air bubbles flows from the
screw.
NOTE: If the primer pump cannot be activated, turn the

engine a small amount.
3. Loosen the bleed screw on the outside of the fuel

injection pump. DO NOT open the fuel return line.
Operate the hand primer pump carefully. Tighten 1
the bleed screw when clear fuel with no air bubbles
flows from the bleed screw.
DCP01767
In-line Fuel Filter Replacement

When replacing the in-line fuel filter, be sure that the arrow on the filter points toward the injection pump.
Changing Hydraulic Oil and Filters
 WARNING: Always stop the engine and engage the parking brake before working on the machine.
 WARNING: Hydraulic tank is a pressurized system. Vent tank before performing work on the
hydraulic system. Use Kit # 323763 when working on the hydraulic system below the tank level.
NOTE: It is advisable to pressure wash the outside and top of the hydraulic tank. Also wash the oil filter
assembly and the area around the oil filter. Do this before starting the following procedure.
NOTE: It is recommended whenever changing hydraulic oil to also replace the hydraulic filters.

1003 - 25
1. Clean the tank top and filter areas before proceeding.
2. Vent hydraulic tank by removing the plug located on the top.
3. Remove safety cap on the bottom of the drain hose, open the drain gate valve on the bottom of the hydrau-
lic tank, and drain the oil into appropriate container.
4. Close drain gate valve on the bottom of the hydraulic tank and install safety cap on the bottom end of the
drain hose.
5. Install new hydraulic oil filter canisters on dual hydrostatic pumps, also install new in-tank filter.
6. The top of the tank should be clean. (Refer to the note above covering pressure washing.)
Remove -12 SAE plug in the top of in-tank return filter and pump oil into tank through this port. Do not drop
foreign material in the tank.
7. Fill the hydraulic oil tank with specified hydraulic oil (approximately 25 gals).
8. Install -12 SAE plug in the in-tank filter.
9. Start engine and run, in neutral, at a minimum engine RPM of 1800 for a minimum of 20 minutes to filter
and warm the oil prior to any operation.
NOTE: There must be oil in the tank when the engine is running. If the pumps do not receive oil, severe pump
damage is possible within 10 seconds.
Hydraulic System Breather

The hydraulic tank is equipped with a screw on canister breather that maintains atmospheric pressure in the
tank. The breather is located on top of the tank. The breather should be replaced if the unit is run in extremely
dirty conditions or once every season.
Spray System
Every 500 hours of operation your spray system should be recalibrated. Refer to the controller manual for
recalibration procedures.
Gear Increaser on Engine

The gear increaser lubricant should be changed after the first 100 hours of operation. Then seasonally or every
500 hours of operation. Use 80W90 GL-5 gear lube.
1. Dipstick
2. Breather
DCP03784

1003 - 26
Hub Lubricant
Replacing Hub Lubricant
NOTE: The oil can be warm so use caution when removing the plug and draining the oil.
1. Put the sprayer on level ground.

2. Turn the hub until the plug is at the bottom.
3. Remove the plug and drain the oil. For best results drain the oil when the oil is warm but use caution when
removing the plug.
4. Now follow the instructions 1-3 under section “Checking Hub Lubricant” to add oil back into the hub.
Each hub with integral brake has a total oil capacity of 58 oz. All four hubs have integral brakes. The oil level in
the hubs should be checked every 50 hours and changed every 500 hours under normal operating conditions.
If the hub is “overfull”, drain to proper level. Recheck two hours later. If it is “overfull” again it is likely the wheel
motor has a shaft seal that is leaking hydraulic oil into the hub. In this case, call your local service
representative.
NOTE: Under high speed use (driving down the road) the planetary gears create heat and pressure in the hub.
This pressure is released around the seal and some oil weeping may occur.
Coolant Filter/Conditioner and Hoses

Your sprayer is equipped with a water filter and
conditioner. The water filter and conditioner removes
foreign material from the cooling system, controls rust,
1
and conditions the coolant to prevent erosion and
cavitation in the cooling system. Use SERVICE filter
Part Number A77544.
Check all hoses and clamps to the coolant system to 2

make sure their is no damage and all clamps are tight.
Install new conditioner filter every time the coolant is

changed and whenever a large amount of coolant is
required.
Remove the Filter DCP01845
1. Close the shutoff valve (Item 1).

2. Use a strap type wrench or filter wrench, Case Part Number CAS-1111 to rotate the filter (Item 2) counter-
clockwise.
Install the Filter
1. Lubricate the gasket on the new filter with coolant or clean oil.
2. Turn the filter clockwise on the threads of the adapter until the gasket makes contact.
3. Tighten the filter 1/2 to 3/4 turn after the gasket makes contact with the adapter. Do not tighten too much.
Do not use a filter wrench to tighten the filter.
4. Open the shutoff valve.
NOTE: Check the antifreeze protection level to be sure it exceeds anticipated ambient operating
temperatures.

1003 - 27
Cab Recirculation Screen

The cab air recirculation screen (Item 1) is located
directly behind the operators seat. The recirculation
screen element must be removed and cleaned each
time the cab outside air filter is serviced. 1
To remove the screen, lift the element straight upwards

far enough to remove the element out one side to clear
the wire harnesses. Use a mild detergent and warm
water to clean the filter. Rinse the element in clear
water, dry and reinstall the element.
Cab Outside Air Filter MK99H026
 WARNING: Cab air filters remove dust in the air, but are not capable of removing chemicals used in
spraying crops or in weed control. Many chemicals used for these purposes are toxic when
improperly used, and can be hazardous to operators and others in the area. Follow the instructions of
manufacturers of both the equipment and the chemicals regarding prohibitions against inhalation of
dust or spray, personal hygiene practices, and other precautions noted by the manufacturers.
 WARNING: This cab is equipped with an activated charcoal filter element that adsorbs pesticides.
DO NOT CLEAN FILTER. Always service with a sealed, factory approved filter element. Dispose of
the used filter element according to federal, state and local regulations. Always follow instructions on
the product label.
The cab filter element must be replaced every year or

after 900 machine hours, whichever occurs first. Follow
these instructions when replacing the filter element:
1. Unlatch the over center latches and remove cover

1
(Item 1).
2. Remove filter element by pulling filter element
straight out of filter housing opening.
3. Clean inside of filter housing of any foreign debris.
Wipe tapered outlet tube with clean dry rag.
4. Remove replacement filter from sealed package.
5. Install new filter element by placing open end in fil-
P0002481
ter housing and seating open end of the element on
the tapered outlet tube. Make sure filter is firmly
seated on outlet tube. The closed end of the filter element will be flush with the open end of the filter hous-
ing when the filter element is properly seated.
6. Reinstall cover and latch with over center latches.
7. Install cab filter service decal, provided with filter, inside the cab on a window in a prominent place. Clean
and dry the glass before applying the decal. Enter machine hour reading and date when filter should be
replaced. The cab filter element must be replaced every year or after 900 machine hours, whichever
occurs first.
8. Dispose of the used filter element according to federal, state and local regulations.
1003 - 28
Engine Air Filter

The engine air cleaner contains 2 elements in the housing. The
outer element is the primary air cleaner and the inner element
is the secondary (safety) air cleaner. When servicing air
cleaners, you must inspect all ducting between the air cleaner
housing and engine intake for air leak that would allow dirt to
enter the engine.
NOTE: The primary element and the secondary element need

to be replaced, not cleaned. It is important that the correct air
filter elements be used as engine failure can be caused by
incorrect filter elements or improper service.
This vehicle is equipped with an air restriction light in the

instrument panel and a restriction indicator on the air cleaner DCP01777
that locks up at the last highest operating condition. The light is
off until air filter is restricted/plugged.
Turbo charged engines must be working under full load to obtain the restricted air flow condition. The air
cleaner restriction indicator shows this condition even after engine is shut down.
Each air cleaner system has a certain amount of built in air restriction even with new filter elements and should
be noted when elements are new and the engine is under full load. This should be about 8.5” H2O on the air
restriction gauge. Temporary conditions such as inlet screen clogged can cause a high reading. The air cleaner
restriction indicator can be reset by pushing the black rubber end cap. Manufacturers service requirements are
25” H2O.
This is the point where the life of the filter element is expended. Additional dirt in the element will cause a rapid
rise in air flow restriction, black smoke, high fuel consumption, and low power.
Operation should not continue or engine damage can occur.
If engine power is low, but yellow is showing in the indicator window - check for a plugged fuel filter.
Reset the air cleaner restriction indicator at each service check. If it does not reset, check for plugged
restriction tap fitting. Check all clamps between air cleaner outlet and turbo charger and tighten if needed.
NOTE: Over servicing should be avoided because this increases the risk for element damage. Avoid opening
the canister or disturbing the element until the air cleaner restriction indicator indicates 20” air restriction.
Service BEFORE the yellow indicator reaches the red line.
Changing the Filter Elements

1. Remove air cleaner compartment cover.
2. Remove the primary filter element by pulling straight out.
3. Remove secondary filter element by pulling straight out.
4. Clean inside of air cleaner body, seal and cover.
5. Install new secondary filter element by pushing straight in. Ensure that element is fully seated in seal.
6. Install new primary filter element by pushing straight in. Ensure that element is fully seated in seal.
7. Install air cleaner compartment cover.

1003 - 29
Coolant Change
To change the engine coolant, do the following:
1. Park the sprayer on a level surface and turn the engine OFF and remove the key.
 WARNING: Check and service cooling system according to maintenance instructions. Hot coolant
can spray out if radiator tank cap is removed while system is hot. To remove radiator tank cap, let
system cool, turn to first notch, then wait until all pressure is released. Scalding can result from fast
removal of the tank cap.
2. Close the valves to the heater core before draining.
2 2
DCP01781
3. Open coolant drain and collect coolant.
DCP01780

1003 - 30
4. Open the oil cooler drain and collect coolant.
5. Close both drains.
IMPORTANT: Never put coolant in a hot engine: The
engine block or cylinder heads can get cracks because
of the difference in temperature between the metal and
the coolant.
DCP01790
6. Open the radiator tank cap and install the proper
type radiator cleaner and fill the system with clean
water. Follow the instructions supplied with the radi-
ator cleaner. The cleaner must be compatible with
the aluminum radiator core.
7. Remove the radiator cleaner solution. Flush the
system with clean water.
6
8. Inspect the hoses and fittings for leaks.
9. Fill the cooling system with the 50/50 coolant solu-
tion specified in this manual and reinstall the radia-
tor tank cap. DCP01778
10. Fill the coolant recovery tank to the proper level and
install the cap.
11. Open the valves to the heater core.
12. Start the sprayer engine and run at low idle for one minute. Stop the engine and add coolant solution to the
coolant recovery tank as necessary.
13. Start the sprayer engine and run the engine to increase the coolant temperature to normal operating
range.
NOTE: If the temperature rises above normal operating range there could be air bubbles in the system that
have to clear. If the temperature does not reach normal operating range, shut your machine off and call your
service representative.
14. Stop the engine and allow the coolant to cool.

15. After the engine is cold, check the coolant level at the coolant recovery tank ONLY. DO NOT remove the
radiator tank cap. If necessary, add coolant solution to the coolant recovery tank. Bring the coolant level to
the proper level.

1003 - 31
AS REQUIRED MAINTENANCE
Hydraulic Part Replacement

Whenever repairing/replacing any hydraulic parts follow these guidelines:
1. Power wash entire machine, especially around area to be worked on.

2. Clean all connections to be removed with an aerosol degreaser and brush before loosening. Repeat flush
with aerosol degreaser with fitting backed out 2-3 turns.
3. Use Kit # 323763 when working on the hydraulic system.
4. Immediately cap or plug any connection that is opened with clean, threaded caps and plugs.
5. Make necessary repairs.
6. Install a new in-tank return filter on the auxiliary hydraulic circuit.
7. Start the engine and run in neutral at a minimum of 1800 rpm.
8. Cycle any cylinder or motor that has been opened, 5 times, through complete stroke, to move any air and
debris to the tank.
9. Allow engine to run, in neutral, at a minimum of 1800 rpm for a minimum of 20 minutes.
Direct Drive Air Compressor / Governor

The optional air compressor supplies air for the foam marker, and it is preset to125 psi. No adjustments are
needed.
Thermostat Check
Check the temperature gauge during engine operation.
If the engine heats slowly, it is possible that the
thermostats are held in an opened position. If the
temperature gauge is in the red area, it is possible that
the thermostats are not operating and are closed.
NOTE: An engine that is not working with a load will be

slow to heat to operating temperature. This is caused by
the large capacity cooling system and is normal. When
the engine has a load, the engine will heat faster.
During cold ambient temperatures, if the sprayer is not DCP01774

moving, run the engine at high idle speed to keep the
engine heated. If the thermostats do not work, replace the thermostats. When the correct engine operating
temperature is not maintained it can cause early engine failure.

1003 - 32
Booms
Boom Breakaways
It is very important that the breakaway locking
mechanism be adjusted so the breakaway section
breaks away only when it encounters an obstruction. It
should not break away under normal operation. Tighten
or loosen the tension bolt (Item 1) to maintain the below
1
dimensions.
310478
Boom Strainers
 WARNING: Strainer may be pressurized. Remove pressure in the feed line before removing
strainer bowl.
 WARNING: If the sprayer contains chemical or fertilizer solution, be sure to wear the appropriate
safety equipment.
Before cleaning boom strainers (Item 1), be sure

pressure has been bled from boom plumbing.
High volume booms have no strainers.
1. Place ignition switch in “RUN” position. Do not start

the engine.
2. Place product pump switch to “ON” and boom valve
switches to “OFF”.
3. Place the product pump switch to “OFF”.
4. Place catch pans under several nozzles on each of
1
the boom sections.
5. Carefully loosen diaphragm caps on the nozzle
bodies located over the catch pans.
6. Allow liquid to drain from the boom plumbing. This DCP01782
may take several minutes.
7. Remove line strainer bowls with care as some product will remain in the strainer housing. Clean screens as
necessary.
8. Reinstall line strainer bowls.
9. Tighten all diaphragm caps which were previously loosened.

1003 - 33
Hydraulic Pump or Motor
Hydraulic Pump or Motor Failure
IMPORTANT: If you suspect a hydraulic pump or motor Grease
failure shut off the engine immediately.
In the event of a hydraulic pump or motor failure, contact

your local service representative.
Hydraulic Pump
Hydraulic Pump or Motor Installation
Grease coupler splines with Texaco P/N 1912, coupler
grease P/N 55089 at time of assembly.
Hydraulic
Wheel Motor
Foam Marker (Turbo)

Checking the Air Supply
1. Disconnect the air supply line from the engine at the air regulator near the foam tank. With the engine at
low idle and under no load there will be no air flow from the airline. Starting at about ¾ throttle without a
load on the engine air will begin to flow and will increase until full throttle. This will be a relatively low
pressure, but should be sufficient to operate the system although somewhat sluggishly. The reason there is
no air flow at a low idle is that the check valve in the line from the engine to the regulator will require from 2
to 3 psi to open. The check valve serves two purposes, 1) to maintain a head of pressure in the tank during
low pressure output from the turbo and 2) most importantly to eliminate any possibility of air moving back
into the engine. Because of this it will be possible to vent the foam tank and fill the foam tank with the
engine running as long as it is at low idle.
2. If no air flow exits under the above conditions. The check valve may be faulty or installed incorrectly.
Troubleshooting the Tank

It should be noted that a low pressure or no pressure reading on the cab gauge during periods of engine idle
should not be cause for concern. This pressure will increase very rapidly when the machine is moved and an
ample supply of air will be available by the time the machine is moved a very short distance. The tank should
hold pressure with the engine off and the system not operating. If this does not happen look into possible loose
or broken air lines or improperly operating air and liquid valves.
Troubleshooting the System

1. Disconnect the Synflex hoses where they mount to the foam mixing chambers on the booms.
2. The larger of the two Synflex hoses is the air supply. It should not have any air flow with the system in the
off position. By turning on the right or left boom, this line should have a continuous flow of air only. Also, this
line needs to snap into the portion of the Tee at the mixing head that goes straight, not the line from the tee
side. When checking this connection into the Tee. The straight inline fitting should have a nozzle like
appearing tip that is screwed into the Tee. This should be noticeable when looking into the fitting.
3. With the same boom selected the smaller of the two Synflex lines should be squirting out a pulsating
stream of liquid. This is controlled by the potentiometer in the cab and should be adjustable from very slow
to quite rapid. If the flow is continuous either the time delay is faulty or the system is hooked up incorrectly.
4. During this entire procedure the opposing boom should not have air flow or liquid flow of any kind.
5. Reattach the Synflex lines making sure the larger line goes to the straight in portion of the Tee and has the
nozzle or venture tip on the fitting inside of the Tee. The system should now make foam and be adjustable.

1003 - 34
Wear Pads on Axle Assembly
If the axles are adjusted frequently the pads will
eventually need replacing. There is a bolt that attaches Wear pads are located
inside the strut
the pads to the frame assembly. As the pads wear the assembly (4 sides)
bolt may rub on the axle assembly. When your axles are
adjusted out you will notice scratch marks on the axle Scratch marks would
tube. Call your service representative when the pads show up on axle tube
if the pads are worn
need replacing.
Grease
Zerk
P0002036

2000
Section 2000
MINOR ENGINE INFORMATION

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Minor Engine Information
2000 - 3
TABLE OF CONTENTS
ENGINE OIL CONSUMPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Problem and Analysis Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Problem and Analysis Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PROBLEM - EXHAUST “SLOBBER”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Causes for Exhaust “Slobber” on Diesel Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

The Facts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
INSPECTING THE DAMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

2000 - 4
ENGINE OIL CONSUMPTION

Problem and Analysis Guide
Before any action is taken on a high oil consumption complaint, it must be determined that a problem exists.
External leaks can appear to be minor, but in fact can be the cause of the loss of a considerable amount of oil
which the operator may complain of as high oil consumption because oil is being added frequently.
Overfilling the crankcase will often result in oil consumption complaints because the excess oil will be blown out
the crankcase breather as a mist due to the oil splash caused by the crankshaft running in the oil. Verify
crankcase blow-by, do this by collecting liquid from the blow-by tube in a 1 gallon plastic jug.
Heavy duty diesel engines are designed to use some oil to properly lubricate the rings and cylinder walls.
Before any repair work is begun to correct an oil consumption complaint, some investigation should be done to
assure there are no leaks, the crankcase is not being overfilled, and the consumption rate is indeed higher than
acceptable.
Checking for Oil Consumption

Oil consumption on diesel engines is based on fuel used and is stated as engine oil/fuel ratio. The typical or
normal oil consumption ratio for diesel engines ranges from .15% to .35%. To obtain the ratio for a specific
engine, consult the engine manufacturers specifications. To obtain an accurate measurement of the engine
oil/fuel ratio, the following guidelines must be followed:
1. Accurately measure oil and fuel used over a period of time and record the measurements on a daily basis.
(Form #3490 is available to record the information.)
2. The engine must have at least 200-250 hours of use or beyond the break in period.
3. The oil used must be of the grade and viscosity specified by the manufacturer.
4. Use proper checking procedure
a. Check oil level with engine at operating temperature.
b. Do not overfill.
NOTE: Thermal expansion from 50° F to 200° F will cause a 5% increase in volume.
5. At the end of the test period, total the number of gallons of fuel and the number of gallons of oil used.
Divide the gallons of oil by the gallons of fuel and convert the results to a percentage.
Example: 200 hours use
1700 gallons fuel used
3.75 gallons oil used
3.75 / 1700 = .0022
.0022 x 100 = .22%
6. Oil consumption rates .50% (.60% for some applications) or above are generally considered to be
excessive and would require engine rework to correct. (Very light lead may be slightly worse not including
oil out blow-by breather.
Reasons for Oil Consumption

1. New engines - short hours:
• Engine not properly broken in. (Engine not being sufficiently loaded.)
• Improper checks as to actual amount of consumption. (See procedure for checking oil consumption
above.)
• External leaks - front or rear seal, etc.
2. Engines with extended use:
• External oil leaks. A few continuous drops of oil add up quickly. (Check crankcase pressure to determine if
a teardown is needed.)

2000 - 5
• Restricted crankcase breather element or tube. High crankcase pressure causes oil to leak at crankshaft
seals.
• Turbocharger. Check oil in the crossover tube or intake manifold which would indicate a turbo seal leak.
• Turbocharge - Excessive exhaust smoke indicating oil carryover into the turbine of the turbocharge due to
worn bearings or seal leakage.
• Worn guides with restricted air intake (NA only).
• Worn piston rings, scored pistons and sleeves (check crankcase pressure before teardown).
Causes:
a. Air induction system admitting dirt. See section on checking this system before teardown.
b. Anti-freeze in oil. See section on checking this system before teardown.
c. Poor engine oil and air cleaner maintenance.
3. Engines recently overhauled:
• Rings improperly installed (inverted top or second rings).
• Worn valve guides - not properly cleaned or improper guide seals used.
NOTE: Use of “will fit” guide seals can “dry up” guides causing greatly accelerated wear in
short hours.
• Cylinder sleeves (worn and scored). Not properly cleaned before installed. Honing (not recommended).
Use of heavy grease on o-rings causing piston or sleeve scoring.
• Debris left in engine during servicing. Valve grinding dust in cylinder head ports. Turbocharger or intake
manifold or pipes not cleaned.
• Air induction system admitting dirt. See section on checking this system before teardown.
• Anti-freeze in engine oil. See section on checking this system before teardown.
• Improper break-in after overhaul. Scoring rings or sleeves by putting on too high a load too soon. Too light
a load to “seat” rings.

2000 - 6
PROBLEM - EXHAUST “SLOBBER”

Causes for Exhaust “Slobber” on Diesel Engines
It is fairly common for a black liquid substance to run out of the exhaust manifold on diesel engines. This
substance is usually thin enough to leak from any joint that is not sealed with a gasket. Some observers have
mistakenly concluded that the “slobber” is engine lubricating oil and that something is wrong with the engine.
They may relate this to oil consumption even when the consumption is within acceptable limits.
The fuel system, combustion chamber and cooling system are primarily designed for good operating
performance under load. When operating at no load or light load, under cool conditions, the volume of fuel
burned is not sufficient to generate high combustion or exhaust temperatures. Water accumulates in the
exhaust system when the exhaust temperatures are insufficient to completely vaporize the liquid. This
combines with any unburned fuel and soot in the exhaust system to produce the black liquid observed during
slobbering.
It will continue until the load and/or operating temperatures are increased sufficiently to vaporize these natural
products of combustion. The exhaust slobber should stop and manifold become dry if the engine is operated
under load sufficient to vaporize the liquid products of combustion.
The Facts
1. Exhaust “slobber” is not unusual and it does not necessarily indicate an engine problem.
2. It rarely contains any engine oil. It is mostly water and soot with some unburned fuel.
3. It occurs at no load, part throttle speeds, but occasionally at high idle, light load, in cool operating
conditions.
Corrective Action
The most effective means of correcting or reducing the problem is to operated the engine under higher loads
which increases the exhaust temperature to dry up the exhaust. However, this may not always be possible.
If customer is required to operate in cool, moist air at partial load and “slobber” is experienced, that he
considers objectionable, operation may be improved by using #1-D fuel.
The condition may also be improved by restricting the air flow to the center of the radiator to raise engine
temperature.
IMPORTANT: Covering only one area of the air flow to the fan can cause high stress on the fan blades. A
round hole in the radiator covering, concentric with the center of the fan, will provide a continuous flow of air to
the fan.

2000 - 7
INSPECTING THE DAMPER

Check the index lines (A) on the damper hub (B) and
the inertia member (C). If the lines are more than 1.59
mm (1/16 inch) out of alignment, replace the damper.
Inspect the vibration damper hub (B) for cracks.

Replace the damper if the hub is cracked.
Inspect the rubber member for deterioration. If pieces

of rubber are missing or if the elastic is more than
3.18 mm (1/8 inch) below the metal surface, replace
the damper.
NOTE: Also look for forward movement of the damper

ring on the hub. Replace the damper if any movement LWF1
is detected.

3000
Section 3000
FUEL SYSTEM

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Fuel System
3000 - 3
TABLE OF CONTENTS
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Common Problems And Solutions.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
In-Line Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Primary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Hand Fuel Primer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3000 - 4
FUEL INJECTION SYSTEM

Common Problems And Solutions.
SYMPTOM
Fog-Like Exhaust In Full-Load Range (White Or Blue)

NOTE: It is assumed that the engine is in good working order and
Poor Performance Or Black Smoke Or Low Power properly tuned, and that the electrical system has been checked and
repaired as necessary.
Rough Idle When Engine Is Warm
Incorrect Idle Or Maximum Speed

Excessive Fuel Consumption
Engine Cannot Be Shut Off
Engine Misses Under Load
Engine Does Not Rev Up

Engine Surges At Idle
Starting Problem
Low Power
CAUSE REMEDY
Improper fuel in tank. Drain tank, fill with proper fuel.
Tank empty or tank vent blocked. Fill tank/bleed system, check tank vent.
Air in the fuel system. Bleed fuel system, eliminate air leaks.
Voltage supply malfunction / stop Correct electrical faults / replace stop

solenoid defective. solenoid.
Fuel filter blocked. Replace fuel filter.
Fuel-supply lines blocked / restricted. Test fuel supply lines-flush / replace.

Loose connections, injection lines leak Tighten the connections, eliminate the
or broken. leak.
Paraffin deposit in fuel filter. Replace fuel filter.
Pump-to-engine timing incorrect. Readjust timing.
Injection nozzle defective. Repair / replace.
Engine air filter blocked. Replace air filter element.
Injection sequence does not corre- Install fuel injection lines in the correct
spond to firing order. order.
Overflow fitting interchanged with inlet Install fittings in their proper position.
fitting.
Cold-start device malfunction Check cold-start mechanism
(If equipped). (If equipped).
Low or uneven engine compression. Repair as necessary.
Fuel injection defective or cannot be Replace.

adjusted.

3000 - 5
FUEL SYSTEM
Fuel Tank Shut-Off Valve
The fuel tank shut-off valve (Item 1) is located at the
bottom rear of the fuel tank.
P0002790
Fuel Tank Drain Plug

The fuel tank drain plug (Item 1) is located on the bottom
rear of the fuel tank.
P0002791
Fuel Tank Vent
The fuel tank vent is located on the fuel tank cap (Item 1).
1
P0002898

3000 - 6
In-Line Fuel Filter
The in-line fuel filter (Item 1) is located just in front of the
fuel tank shut-off valve.
P0002790
Primary Fuel Filter

The fuel filter (Item 1) is located towards the back, on the
left side of the engine.
Fuel filter drain (Item 2).
P0002796
Secondary Fuel Filter

The secondary fuel filter (Item 1) is located just in front of
the primary fuel filter.
P0002796

3000 - 7
Hand Fuel Primer
The hand fuel primer (Item 1) is located under the fuel
filter.
P0002793

4000
Section 4000
ELECTRICAL SYSTEM

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Electrical System
4000 - 3
TABLE OF CONTENTS
GENERAL ELECTRICAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Electrical Circuits Compared to Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ELECTRICAL SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ELECTRICAL REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Test Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Self-powered Test Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Fused Jumper Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Multimeter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
CIRCUIT FUNDAMENTALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
TROUBLESHOOTING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TROUBLESHOOTING TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . 18
RELAY IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
FUSE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
QUICK REFERENCE TO TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
QUICK REFERENCE TO CONNECTOR LOCATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . .27
CONNECTOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Bulkhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Duetsch Test Adaptors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Boom and Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
PCP Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Pressure Limiter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Load Share (Qty. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Product Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pump On Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sparge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Product Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Remote Station Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Boom Section Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Foamer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Service Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ladder Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Ballast Lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4000 - 4
Front Work Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Head Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Radar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Auxiliary Boom Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Tail Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Boom Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Reverse Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Boom Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Boom P.S.I. Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hydraulic Filter Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hydraulic Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4000 - 5
GENERAL ELECTRICAL INFORMATION

Electrical Circuits Compared to Hydraulic
Electrical circuits are considered hard to understand because we cannot see anything happening.
For instance if we take one end of a wire and attach it to a 12 volt source, turn on the switch, nothing
appears to be happening at the open end of the wire. However, if we take one end of a hydraulic
hose and connect the other end to a source, turn on the valve, the result will be hydraulic fluid flowing
out of the hose. You can clearly see the results with hydraulic fluid.
The hydraulic hose has pressure pushing the oil through it. The wire has voltage pushing the
electrons through it. The only difference is that at the end of the wire the voltage cannot push hard
enough to force the electrons out of the wire in most cases.
Both electrical voltage and hydraulic fluid need a path to follow to make them useful.
Many of the fundamental principles are the same, just different terminology. Examine the following
descriptions of the basic units of measure in each system.
Both systems use a measurement of flow –
Hydraulics uses a quantity of fluid, typically gallons or liters, moving past a given point in a known
amount of time, usually one minute, to quantify the flow. Usually this is given in terms of Gallons Per
Minute (G/min) or Liters Per Minute (L/min).
Electronics uses the same principle except electrons (typically) are the object of the flow
measurement. The unit used to measure the quantity of electrons is the Coulomb; there are
6,280,000,000,000,000,000 electrons in one Coulomb. When one Coulomb of electrons passes a
given point in one second, a current of one Ampere is flowing in the circuit. Amperes are commonly
abbreviated as Amps.
Both systems have a unit of pressure –
Electronics uses the Volt to measure electrical pressure or potential. The Volt also has ties with the
Coulomb. When force of one Joule (a metric unit of work similar to the foot-pound in English
measure) has moved one Coulomb of electrons from one point to another, a potential of 1 Volt has
been produced.
Hydraulics also has a measurement of pressure. The measurement is based upon force applied per
unit of area. The term to describe the amount of pressure depends on the system of measurement,
typically pounds per square inch in English measure and bar in the metric system.
Both systems have a unit of resistance –

In hydraulics, the “resistance” of a particular component such as a hose is called the pressure drop.
The amount of pressure drop depends on factors similar to those of the Ohm. The length, cross-
sectional area, and viscosity of the fluid (temperature dependent) are some, but not all, factors that
affect pressure drop.
Electrical systems and electronics typically measure resistance in Ohms. The amount of resistance
of any conductor depends on its length, cross-sectional area, and resistivity. Resistivity is a
parameter that depends on the molecular structure of the material and the temperature.
As you may have noticed, hydraulic units of measure change depending on the system of
measurement. However, electricity and electronics use a more “universal” language. Volts are Volts
no matter where in the world you are; same with Ohms and Amperes.

4000 - 6
ELECTRICAL SYMBOLS
Quick Reference Guide
Battery Switch N.O. SPST
Fuse
Switch N.O. SPST
Momentary On
Junction Point
Circuit Ground
Switch SPDT
Earth Ground
Auto Reset
Circuit Breaker
Switch DPDT
Terminal Block
Relay Coil Switch, Temp, N.O.
Relay Contact N.O. Switch, Level, N.C.
Relay Contact N.C. Switch, Pressure, N.C.
Resistor Switch, Foot, SPDT
Variable Resistor Single Filament Lamp
Solenoid Multiple Filament Lamp
Speaker Diode
Flasher
Rotary Switch 3 Position
Connector
Rotary Switch 4 Position Connector

4000 - 7
ELECTRICAL REVIEW
The main source must be present or electrons cannot flow in the wire. The
source in our system is a 12 volt DC battery.
Ground must also be present. The ground completes the circuit or path.
The circuit must be a complete path for the electrons to flow. If there is not
a complete path the component will not work.
Lamp
Battery
Ground Ground
On our electrical schematics, ground symbols are used for convenience to show common grounding
points without drawing the line.
The load (resistance) must be present.
• If the load is bypassed (shorted) too much current will flow and damage to
the circuit components may occur,
• If the load is open no current can flow and the circuit cannot perform the
work.
“S1” is a switch which can be opened or closed as desired. When “S1” is open current will not flow to
the light, so the light will be off. When “S1” is closed current will flow to the light turning the light on.
Lamp
Battery
S1
Open
Ground Ground
Lamp
Battery S1
Closed
Ground Ground

4000 - 8
A fuse protects components if a short circuit should occur. In other words, the fuse will “blow” before
the light (load) or wiring is ruined.
Lamp
Battery S1
Fuse Closed
Ground Ground Ground
A short circuit is when too much current is being drawn and can damage components in your system.
An open circuit is zero current flow, which does not damage components, but the circuit will not work.
Formulas to remember:
E
I R
E=IxR Voltage = Current x Resistance

I = E/R Current = Voltage/Resistance
R = E/I Resistance = Voltage/Current
TROUBLESHOOTING TOOLS
Test Light
A test light can be used to check for voltage. A test light is merely a small light bulb (of the proper
voltage) with a pair of wire leads attached. After grounding one lead, the other lead is touched to
various points along the circuit where voltage should be present. Of course, when the light comes on
voltage is present at the point being tested.
While a test light can indicate the presence of voltage, it cannot indicate how much voltage. A test
light in a 12-volt circuit that "seems about one-half lit up" does NOT indicate 6 volts in the circuit. Six
volts applied to a 12-volt test light will cause the bulb to barely glow.
A technician must be very careful when using test lights for troubleshooting. An increasing number of
circuits have solid-state components and or microprocessor/computer controls. Using a test light can
very easily damage these types of circuits. The low resistance of the bulb can allow too much current
to pass in the circuit and cause damage to the electronic devices. If the circuit is not immediately
damaged by the test, often the results are meaningless anyway because the current in the circuit is
so low that the bulb will not light. Electronic circuits must always be tested with a high-impedance
digital multimeter.

4000 - 9
Self-powered Test Light
Some models of test lights have a battery incorporated into them. If the test light leads are touched
together the bulb will glow. Self-powered test lights are used only on non-powered circuits and are
used to check for continuity in circuits. Select two specific points in the circuit where there should be
continuity. Connect one lead of the self-powered test light to each point; if there is continuity the
circuit will be completed and the test light bulb will glow.
Never use a self-powered test light on circuits that may contain solid-state components, electronic
devices, or microprocessors/computers; serious damage to these types of components may result.
Fused Jumper Wire
A fused jumper wire is merely a fuse holder with alligator clips attached to the leads. Fused jumpers
can be used to temporarily bypass segments of a circuit for troubleshooting purposes. NEVER use a
fuse in the jumper with a higher rating than the fuse that normally protects the circuit being tested.
Do NOT use fused jumpers in any instance to apply power to the input or output of an ECU or any
other microprocessor/computer device.
Multimeter
The multimeter is truly a universal test device for electrical circuits. Nearly all multimeters can take
measurements of the three basic parameters of an electrical circuit - voltage, current, and resistance.
Although analog multimeters are still available and have benefits in certain applications, most
references to multimeters imply a digital multimeter unless specifically noted.
A multimeter is always helpful in diagnosing electrical problems, but it is an absolute necessity when
it comes to testing circuits with microprocessor or electronic components. The high input impedance
of a multimeter prevents any significant current to develop in the circuit. Therefore, a multimeter
virtually eliminates damage to electronic devices when testing circuits.
CIRCUIT FUNDAMENTALS
Current is measured in amperes (amps). Measurements of less than one are

measured in milliamps (thousands of a amp). For example 200mA =.2 amps.
Note: Your meter may not be able to handle current in excess of 100mA. Be
certain to know how much the meter will handle and what you expect to see
before measuring the current.

4000 - 10
Voltage is measured in volts. Be sure to set the meter to the correct scale before
measuring the voltage. Know the maximum voltage of the system (SPX Series is
12 volts nominal).
Resistance is measured in ohms. Be sure to set your meter to the correct scale
before for measuring the resistance you expect.
NOTE: Be sure to shut off power before measuring resistance or you may
damage your meter.
To measure voltage the meter must be connected in parallel with the circuit.
• The meter only reads differences in potential.

• If you connect the red lead to ground and the black lead to hot the meter will deflect below zero (if
analog); and if digital read the correct voltage with a negative sign -12 volts.
• If read across the battery you will read the source voltage.
• If read across S1 closed you will read zero; and across S1 open 12 volts.
• If read across the fuse you will get zero unless the fuse is open then you will get 12 volts.
• If read across the bulb you will get near source voltage if it is good and full source voltage if it is
bad.
• If read across a good piece of wire zero volts and if read across and open piece of wire 12 volts.

4000 - 11
To measure current the meter must be connected in series with the circuit.
• Current is common in a series circuit and will be the same regardless of where it is tested.
• Current must be measured at a break in the circuit where the meter is added. The circuit must be
broken and the meter added in series so that all current flowing in the circuit is going through the
meter for an accurate reading.
To measure resistance we must be connected in parallel with the circuit.
NOTE: When measuring resistance, turn off the power to the circuit or you may damage the meter.
When measuring resistance the meter uses its own internal battery to cause current flow
through the component or circuit under test. If you test a component “in circuit” where more
than one path is available it will measure the resistance of all the paths.

4000 - 12
• If you reverse your leads you will not know unless you are testing a diode. When testing a diode,
test it with leads in one direction then swap leads to the other direction, you should see a high
reading in one direction and a low in the other.
• If read across the battery you will not get a good reading and could damage your meter.
Do not do this!
• If read across “S1” closed you will read zero ohms; and across “S1” open a high value near
infinity.
• If read across the fuse you will read zero ohms unless the fuse is open in which case you will get
a high value near infinity.
• If read across the bulb you will get near 1-4 ohms if it is good and a high reading near infinity if it
is bad.
• If read across a good piece of wire zero ohms and if read across an open piece of wire you will
get a high reading near infinity.
TROUBLESHOOTING PROCEDURES
Use the following 4-step approach when troubleshooting.
Step 1: Check the problem
Perform a system check to be sure you understand what is wrong. It is a good idea to have the
complaint duplicated by the customer if possible. Often times the problem description you are
provided is only part of the story. Don't waste time fixing part of the problem! Do not begin
disassembly or testing until you have narrowed down the possible causes.
Step 2: Read the electrical schematic
Study the schematic; try to gain an understanding of how the circuit should work. Check circuits that
share wiring with the problem circuit. Try to operate the shared circuits, they can be identified on the
wiring schematic. If these circuits work, then the shared wiring is OK. The cause must be in the
wiring used only by the problem circuit. If several circuits fail at the same time, chances are the power
(fuse) or ground circuit is the cause.

4000 - 13
Step 3: Find the cause and repair it
¸ Narrow down the possible causes

¸ Isolate the problem circuit(s)
¸ Make necessary circuit measurements outlined on the schematic
¸ Before replacing a component, check power, signal, and ground wires at the component
harness connector. If these are OK, chances are the component is bad.
Step 4: Test the repair
Repeat the system check to be sure you have fixed the whole problem.
TROUBLESHOOTING TESTS
Testing for continuity
1. Disconnect the battery.

2. Connect one lead of a self-powered test light or ohmmeter to one end of the part of the circuit
you wish to test.
3. Connect the other lead to the other end of the circuit.
4. If the self-powered test light glows or the ohmmeter reads low or no resistance means good
continuity.
Continuity test of a 3-position

single pole switch
Set meter to ohms or continuity
function.

4000 - 14
Testing for voltage drop
This tests for voltage being lost along a wire or through a connection or switch.
1. Connect the positive lead of a voltmeter to the end of the wire (or to one side of the connection
or switch) that is closer to the battery.
2. Connect the negative lead to the other end of the wire (or to one side of the connection or
switch).
3. Operate the circuit.
4. The voltmeter will show the difference in voltage between the two points.
Voltage drop test of simple circuit

Positive lead
Set meter to volt measurement battery side
function.
Lamp
Battery
Fuse S1
Ground Negative lead Ground

load side
Testing for short to ground
Use a test light or voltmeter.
A test light works very well for the following procedure:
1. Remove the blown fuse and disconnect the load.

2. Connect a test light or voltmeter across the fuse terminals (be sure there is power at the fuse).
3. Beginning near the fuse block, wiggle the harness from side to side. Continue this at
convenient points (about 6 inches apart would be ideal) while watching the test light or
voltmeter.
4. When the test light glows, or the voltmeter registers, there is a short to ground in the wiring near
that point.
Testing for short with voltmeter or test light
Set meter to volt measurement

function.
Remove Fuse Lamp

Battery Fuse S1

Short to ground Load disconnected

4000 - 15
Use a self-powered test light or ohmmeter.
1. Remove the blown fuse and disconnect the battery and load.
2. Connect one lead of a self-powered test light or ohmmeter to the fuse terminal on the load side
of the fuse.
3. Connect the other lead to a known good ground.
4. Beginning near the fuse block, wiggle the harness from side to side. Continue this at
convenient points (about 6 inches apart would be ideal) while watching the self-powered test
light or ohmmeter.
5. When the self-powered test light glows, or the ohmmeter registers, there is a short to ground in
the wiring near that point.
Testing for short to ground with ohmmeter or

self-powered light
Set meter to ohms or continuity

function.
Same as
meter
Battery disconnected Lamp

at ground Remove Fuse
Battery
Fuse S1

Short to ground
Load disconnected

4000 - 16
When fuses power several loads.
1. Use the schematic to identify the circuits associated with the fuse that has blown.
2. Open the first connector or switch leading from the fuse that is common to each load.
3. Replace the blown fuse.
• If the fuse blows, the short is in the wiring leading to the first connector or switch. Use a test
light or meter as described above.
• If the fuse does not blow, go on to the next step.
4. Close each connector or switch until the fuse blows to find which circuit the short is in. Connect
the test light or meter at the connector to the suspect circuit (disconnected) rather than at the
fuse terminals. Proceed along the circuit using this method until the short is found.
Testing for short to ground with several loads

or same fuse
Set meter to volt measurement

function.
Lamp 1
S2
Lamp 2
Battery S1 S3
Lamp 3
Ground Remove Fuse
S4
Common point circuits will have to be Ground Ground

isolated at this point to find short. Short to ground

4000 - 17
Testing for current
To test for current the meter must be connected in series in the circuit. Current measurements
normally involve a component being removed or disconnected from the circuit. The circuit current
flows through the meter, which displays the current in amps or milliamps. The meter should have a
rating higher than the expected current.
NOTE: Never use a meter set to a current scale to measure voltage. Severe damage to the meter,
the circuit, or both will result.
Two commonly used locations for taking current measurements are at a fuse and at the battery.
Measuring current in a circuit
Set meter to current measurement

function.
OR
Lamp
Battery S1
Fuse
+ -
Ground Ground

4000 - 18
ELECTRICAL SYSTEMS SCHEMATICS AND DIAGNOSTICS

Power Distribution System Circuit Operation
Power distribution consists of the following:
1. Unswitched battery power. Unswitched power is available at all times. The battery positive terminal is
connected to the unswitched power bus from which all unswitched power circuits are energized.
Power is available to all of the following fuses F1 - F14 regardless of the ignition switch position.
2. Switched battery power. This power is supplied to the system when the ignition system in ON. This
switching is controlled by relay.
When the ignition is switched ON the cab power relay is energized, supplying battery power to the switched
power bus which in turn supplies power to fuses F15 - F23. Additionally the controller relay is energized and
power is distributed to.
Power Distribution Circuit Troubleshooting

Before troubleshooting the power distribution system make sure that the following operating conditions are
met:
1. The batteries are fully charged and all connections are clean and tight.
2. Transmission in neutral or park.
3. Check all connectors for full installation, loose, corroded or pushed out terminals.
4. Determine if the power source being investigated is switched or unswitched.
5. If the power source problem is a switched power source, the relay controlling the circuit needs to be
determined and tested.

4000 - 19

4000 - 20
RELAY IDENTIFICATION
413189A3
Item # Component Description Item # Component Description
R1 High Beam Relay R23 Cab Pressurization Relay
R2 Rear Work Light Relay R24 Left Inner Out

R3 Ignition Switch Power Relay R25 Left Inner In
R4 ECU Power Relay R26 Left/Right Foam
R5 Accessory Power Relay R27 Left Level Down

R6 Rear Roof Worklights Relay R28 Left Level up
R7 Neutral / Not Neutral Relay R29 Spread/Hold
R8 Neutral Start Relay R30 Right Inner Out

R9 Front Roof Worklights Relay R31 Not Used
R10 Front Center/Side Worklights Relay R32 Not Used
R11 Worklight Interlock Relay R33 Right Inner In
R12 Park Brake Lockout Relay R34 Right Level up
R13 Boom Light Relay R35 Right Level Down
R14 Headlight Relay R36 Not Used
R15 Park Brake Relay R37 Not Used
R16 Backup Relay R38 Not Used
R17 Service Brake Relay R39 Autocenter Right
R18 Open R40 Autocenter Left
R19 Open R41 Autocenter On/Off
R20 Open SC Service Connector

R21 Brake Light Relay DR Headlight Dipping Relay
R22 SOX Controller Power Relay F Electronic Flasher (Not Shown)

(Located Below Relay/Fuse Assy. Panel)

4000 - 21
FUSE IDENTIFICATION
413189A3
Fuse No. Amp/Size Circuit Identification Fuse No. Amp/size Circuit Identification
1 10 Ignition Switch 29 20 Front Wiper B+

2 10 Radio / Dome / Map Lights 30 20 Rear Wiper B+
3 30 Boom Lights 31 5 Load Share
4 20 Accessory Power Ports 32 15 Blower Cab Pressure
5 10 Horn 33 20 Accessory Power Ports
6 25 Electronic Flasher 34 15 Elec Mirrors
7 30 Headlamp Circuit 35 10 Seat Heater B+
8 5 Service Tool 36 10 Chassis Sensors / Radar

9 10 ICU Display 37 10 ICU Display
10 10 Brake Lights 38 5 CDB Battery
11 Open 39 15 Neutral / Not Neutral B+
12 10 Cigar Lighter 1 40 RH Console

15 30 Worklights, Rear Roof 43 RH Console
16 30 Worklights, Front Roof 44 Open
17 20 Worklight Interlock Relay 45 20 Running Lights

18 RH Console 46 15 Left High Beam
19 15 Seat Power 47 15 Right High Beam
20 RH Console 48 15 Left Low Beam
21 RH Console 49 15 Right Low Beam
22 10 Hold Solenoid 50 25 Right Front Worklights / HD
23 15 Business Band 51 25 Left Front Worklights

24 10 Propel Controller 52 10 Headlight / Tail / Pos / Hazard
25 5 HVAC F’/C’ Conversion 53 RH Console
26 30 HVAC Module ATC 54 Open
27 5 HVAC Microprocessor B+ 55 30 B+ Headlights
28 10 Beacon / Strobe Lamp 56 5 Ind Lamp / Gauge Power

4000 - 22
QUICK REFERENCE TO TROUBLESHOOTING

The following chapter covers common problems that might occur on your vehicle with probable causes and
suggested corrective action.
The troubleshooting listings are theoretical, systematic, searches for malfunctions in your vehicle. If all
symptoms are known and properly diagnosed, it is relatively easy to determine what component is
malfunctioning and what corrective action is required to restore your machine to proper operation.
Your sprayer consists of five major components not including optional equipment:
1. Engine
2. Hydraulic System
3. Electrical System
4. Liquid Spray System
5. Rate Controller
The sprayer has the following self-diagnostic equipment installed to simplify troubleshooting of the machine.
• Amp gauge
• Fuel gauge
• Engine temperature gauge
• Engine oil pressure gauge
• Air cleaner restriction indicator and light
• Hydraulic oil tank level sight gauge and light
• Hydraulic oil temperature gauge and light
• Hydraulic system charge pressure light
• Hydraulic oil return filter light
• Charge filter light
• Sparge pressure gauge
• Boom pressure gauge
• Foam Marker gauge

4000 - 23
Item Section-Page No. Symptom Probable Cause Corrective Action
Axles 4000-22 Axles do not extend or Wiring not functioning Check wiring operation -
retract properly. correctly. unloader valve should
open when axle is
extended and when
retracted.
Faulty axle adjustment Replace switch.

switch.
Faulty in/out or unloader Faulty in/out or unloader

solenoid. solenoid.
Hydraulic system. If wiring checks out - check

hydraulic system.
Boom Section Valves 4000-28 Boom controls do not work Faulty wiring. Check wiring.
- other functions o.k.
Faulty handle. Check wiring at handle with

test light.
Controller faulty or setup Check setup and replace if

improperly. needed.
No power to Pin A of Fuse blown or broken Replace fuse- check for

connector. wire(s). broken wire(s), replace as
needed.
No power to Pin C of Master switch in wrong Place switch in correct
connector. position. position.
Blown fuse. Replace fuse.

Booms Up / Down 4000-22 Boom controls do not work Faulty wiring. Check wiring.
- other functions o.k.
Boom Functions 4000-34, 35 Faulty handle. Check wiring at handle with

test light.
Controller faulty or setup Check setup and replace if

improperly. needed.
Boom controls do not work Ball valve fuse or faulty ball Replace fuse or valve.
on single sections. valve.
Faulty wiring. Check wiring.
Improper controller setup. Check setup.
Boom folding functions do Hydrostat not in neutral. Position hydrostat in

not work - other functions neutral.
o.k.
Boom folding functions do Faulty switch. Replace switch.

not work - other functions
o.k.
Faulty in/out solenoid. Replace solenoid.
Boom functions do not Faulty switch. Replace switch.

work other functions o.k.
Boom is not sitting straight. Faulty micro switch. Replace micro switch.

4000 - 24
Boom Functions 4000-34, 35 Boom is not sitting straight. Switch out of adjustment. Adjust gap between micro
switch and plate.
Boom functions do not Faulty in/out solenoid. Replace solenoid.

work other functions o.k.
Boom fold, boom function, Faulty unloader solenoid. Replace solenoid.

axle function, all fail to
operate.
PCP Valve 4000-24 System will not operate in A problem in the wiring or Check SX controller I.D.
either direction continued. the SX controller. lights, determine fault code
flashing. Reference SX
controller service manual
for code identification.
Contact your local service
representative.
P.S.I. Limit 4000-24 RPM’s higher than normal Faulty P.S.I. Limit Replace P.S.I. Limit.
when placed in reverse.
Faulty coil. Replace coil.
Charge Pressure 4000-24 Warning light in cab on. Blown fuse. Replace fuse.
Low pressure. Hydraulic problem.
Load Share 4000-25 Machine pulls to one side Faulty coil. Replace coil.
or the other while going
down the road. Faulty Traction Control Replace switch.
Switch.
Hydraulic system. Electrical checks out,

check hydraulic system.
Product Pump 4000-25 Product Pump Light on in Faulty switch. Replace switch.
cab.
Blown fuse. Replace fuse.
Faulty coil. Replace coil.
No pressure. Hydraulic problem.

Pump On Sensor 4000-25 Product Pump Light on in Faulty sensor. Replace sensor.
cab, system still spraying
full.
Sparge Valve 4000-26 Gauge in cab not showing Faulty fuse. Replace fuse.
pressure.
Faulty sensor. Replace sensor.
Faulty gauge. Replace gauge.

Hydraulic system. Electrical checks out,
check hydraulic system.
Product Control Valve 4000-26 Controller showing error. Remote station switch S1 Place switch in correct
in wrong position. position.
Remote station switch S2 Place switch in correct

in wrong position. position.
No power to valve. Check for power at the
driver.
No power at driver. Check for power at remote

station.
Faulty S1 switch at remote Replace switch.

station.
Faulty S2 switch at remote Replace switch.

station.
No power at remote Check connections to the

station. controller. Tighten if
needed.

4000 - 25
Product Control Valve 4000-26 Controller showing error. Hydraulic system. Electrical checks out,
(Cont’d) check hydraulic system.
Remote Station Power 4000-28 No power at remote Loose or broken wire(s) Check wiring tighten or
station. from controller. replace as needed.
Foamer 4000-31 Foam marker fails to Faulty fuse. Replace fuse.

operate.
Faulty switch in pistol grip. Replace switch.
Faulty foam marker control (Contact your local service

circuit. representative.)
Foam marker fails on right Faulty right hand foam Replace relay.
side. motor relay.
Faulty solenoid. Replace solenoid.
Foam marker fails on left Faulty left hand foam motor Replace relay.
side. relay.
Faulty solenoid. Replace solenoid.

Faulty switched power to Faulty fuse or relay. Replace as needed.
fuses.
Faulty switched power to Faulty fuse or relay. Replace as needed.

one of the switched power
bus bars.
Faulty switched power at all Faulty circuit breaker on Replace breaker.

above locations. block.
Low quantity of foam and Large and small lines at the Looking at the tee, the
very wet. mixing heads are large line supplying air to
interchanged. the mixing head must
come into the straight
portion of the tee and not
the one at a 90 deg. angle.
Missing or broken venturi Replace fitting with proper
at the tee to the mixing part if broken or missing.
head.
Possible “foam lock” of Purge line by removing the

supply line. line at the mixing head until
foam is purged from the
line.
No Foam. Pump not running. Check pump with engine

off and foamer pump
switch on.
Solenoid valves sticking. Check 3-Way valve on

center section and 2-Way
air valve on boom.
Service Brake Switch 4000-31 System will not operate in Faulty switch. Replace switch.
either direction.
Ladder Down 4000-31 Ladder not operating.
Ballast Lamp 4000-32 Lamp not operating. Switch in wrong position. Place switch in correct
position.
Faulty relay. Replace relay.
Faulty ballast / lamp. Replace ballast / lamp.
Faulty switch. Replace switch.

Faulty or corroded wiring. Check wiring, repair or
replace as needed.
Front Work Lamps 4000-32 Lamps not operating. Faulty relay. Replace relay.

4000 - 26
Front Work Lamps 4000-32 Lamps not operating. Switch in wrong position. Place switch in correct
position.
Faulty lamp(s). Replace lamp(s).

replace as needed.
Head Lights 4000-32 Lights not operating. Switch in wrong position. Place switch in correct
position.
Faulty light(s). Replace light(s).

replace as needed.
Auxiliary Boom Lights 4000-33 Lights not operating. Switch in wrong position. Place switch in correct
position.
Faulty light(s). Replace light(s).


replace as needed.
Tail / Brake Lights 4000-34 Tail / Brake lights not Faulty relay. Replace relay.
operating.
Faulty fuse. Replace fuse.
Faulty bulb. Replace bulb.
Horn 4000-33 Horn not operating. Faulty fuse. Replace fuse.

Faulty horn. Replace horn.

replace as needed.
Radar 4000-33 Controller not operating. Loose connection at the Tighten connection.
controller.
Faulty radar. Replace radar.

Boom Pressure Sensor 4000-36 No pressure on gauge. Faulty sensor. Replace sensor.
Faulty fuse on gauge. Replace fuse.

replace as needed.
Reverse Alarm 4000-36 Alarm not operating. Faulty reverse switch. Replace switch.
Reverse switch out of Adjust switch.

adjustment.
Faulty alarm. Replace alarm.

replace as needed.
Boom P.S.I. Switch 4000-39 No spray from center Switch in wrong position. Place switch in correct
section. position.
Flow Meter 4000-39 Controller not metering Faulty or corroded wiring. Check wiring, repair or
flow. replace as needed.
Faulty flow meter. Replace flow meter.

4000 - 27
Hydraulic Filter 4000-40 Low pressure light in cab is Faulty wiring. Check wiring.
Restriction on.
Hydraulic Oil Level / 4000-41 Hydraulic Oil Level light System low on fluid. Stop engine!
Temp comes “ON”. Check the oil level at sight
gauge in the tank.
If the oil level is low:
Check for oil leaks and
repair area leaking.
Fill oil tank to proper level.
Hydraulic Oil Temp light Fluid temperature too high. Check the temperature of
comes “ON”. the oil at the sight gauge. If
the temperature of the oil is
above 200° F, call your
local service
representative.

4000 - 28
QUICK REFERENCE CONNECTOR LOCATIONS

CONNECTOR INFORMATION
Bulkhead Connector Schematic

Connectors
Location No. Location
Axle Out BH7 J403 E11
Axle In BH7 J404 E11
Booms Up BH4 J55 H17
Booms Down BH4 J56 H17
PCP Valve BH7 J405 G10
P.S.I. Limit BH7 J416 D10
Charge Pressure BH7 J419 F9
Load Share (Qty. 2) BH7 J417 E11
Product Pump BH5 J76 G17
Pump On Sensor BH5 J500 B10
Sparge Valve BH5 J77 G17
Product Control Valve BH5 J74 H15
Remote Station Power BH7 J401 G15
Boom Section Valves BH5 F14
Foamer (Left/Right Liquid Foam) BH4 J61 F17
Foamer (Left Air Foam) BH4 J63 E17
Foamer (Right Air Foam) BH4 J64 F17
Service Brake Switch BH6 J319 F10
Ladder Down BH6 J306 F10
Ballast Lamp BH6 J313 H6
Front Work Lamp (Left) BH6 J315 G6
Front Work Lamp (Right) BH6 J317 G6
Head Light (Left) BH6 J314 E4
Head Light (Right) BH6 J316 E4
Horn BH6 J305 F4
Radar BH7 J425 E9
Auxiliary Boom Light (Left) BH7 J426 H11
Auxiliary Boom Light (Right) BH7 J426 H11
Tail Light (Left) BH7 J2 G6
Tail Light (Right) BH7 J3 G6

4000 - 29
CONNECTOR INFORMATION
Bulkhead Connector Schematic

Connectors
Location No. Location
Tail Light (Neutral Wire) BH7 J406 G6
Boom Pressure Sensor BH5 J91 A10
Boom Functions BH4 D16
Reverse Alarm BH7 J409 D10
Boom P.S.I. Switch BH5 J501 B10
Boom P.S.I. Switch (Optional) BH5 J502 B10
Flow Meter BH5 J75 H14
Hydraulic Filter Resistor BH7 J411 F9
Hydraulic Level BH7 J412 F9
Cab Harness 1
Power C88
In/Out Interface C89
Controller Interface C97
Boom Shut-Off Sensors C96
SX Controller C100 J24
(If Equipped) C106
Cab Harness 2
Light Cluster C70/71
Gauge Set Wires C103

4000 - 30
CONNECTOR TESTING
Bulkhead
1. BH1 - (+) Positive 2
2. BH2 - (-) Negative
1
3. BH3 - AIM Command (Option)
4. BH4 - Hydraulic
5. BH5 - Product Controls
6. BH6 - Front Frame 7
8
7. BH7 - Rear Frame
6 3
8. BH8 - Engine 5 4
Main Harness contains 1,2,6,7 and 8 listed above.

P0002522
Application Harness contain 3,4 and 5 listed above.
Duetsch Test Adaptors

A complete set of Test Adaptors can obtained through
the service department.
These breakout adaptors allow for both inline

monitoring and/or point monitoring (if other end is left
unconnected).
These adaptors can greatly increase effectiveness.
P0002552
Boom and Axle

1. Booms Up (J55) contains 1 Blue and 1 Black wire.
Booms Down (J56) contains 1 Blue wire with a
Black Stripe and 1 Black wire.
2. Axles In (J404) contains 1 White wire with a Red

Stripe and 1 Black wire. 3 1
Axles Out (J403) contains 1 White wire with a Red
Stripe and 1 Black wire. 2
3. Optional (Future/Not used).

P0002560
Testing
• Should have +12V at the connector while appropriate function is used.
• Coils should measure 10-25 Ohms.

4000 - 31
PCP Valve
1. PCP Valve (J405) contains 1 Blue, 1 Yellow wire,
and the 2 center wires are Black with a White
Stripe.
NOTE: PCP Valve is Equipped with manual override, to

determine if problem is electrical or hydraulic. 1
CAUTION: Never use manual override unless control

ports are capped with gauges installed or machine is on
stands with the tires removed.
P0002524
Testing
• Computer Controlled / Current Controlled.
• Use an Adaptor with LED lamps.
Pressure Limiter Valve

1. P.S.I. Limit (J416) contains 1 Red wire with a White
Stripe and 1 Black wire.
Testing
• Should have +12V while in reverse only.
P0002526
Charge Pressure
1. Charge Pressure (J419) contains 1 White wire with
a Red Stripe and 1 Green wire.
NOTE: This switch is normally closed during operation.

1
Testing
• Should have a 0 voltage drop during normal opera-
tion, or +12V voltage drop with engine shut off.
P0002527

4000 - 32
Load Share (Qty. 2)
1. Load Share (J417) contains 1 White wire with a
Red Stripe and 1 Black wire.
NOTE: Load Share is normally open during operation.
Testing
• Should have +12V only when Traction Control Floor
Switch is depressed. 1
P0002528
Product Pump
1. Product Pump (J76) contains 1 White wire with a
Testing
• Should have +12V when Pump On/Off switch is in 1
the On position.
• Should measure 10-25 Ohms.
P0002532
Pump On Sensor
1. Pump On Sensor (J500) contains 1 Green and 1
White wire with a Red Stripe.
NOTE: This a normally closed switch, opens with 5 lbs.

of pressure.
1
Testing
• Should have +12V only when Pump On/Off switch
is in the On position.
NOTE: The Pump On Sensor receives power through P0002533

the Product Pump Switch.

4000 - 33
Sparge Valve
1. Sparge Valve (J77) contains 1 Green and 1 White
wire.
Testing
• Should have ± 12V depending on position of INC /
DEC switch on sparge adjustment.
P0002534
Product Control Valve

1. Product Control Valve (J74) contains the following
wires.
1 White wire with a Red Stripe (positive) that is part
of BH4.
1 Black wire (negative).
1
1 Brown wire with a White Stripe.
1 White wire with a Black Stripe.
1 Grey wire with a White Stripe.
Testing P0002535
• Should have +12V with red lead on A and black on
B.
• Depending on position of INC / DEC switch on the product controller, C and D should have ± 12V.
Remote Station Power

1. Remote Station Power (J401) contains 1 White wire
with a Red Stripe and 1Black wire.
Testing: Should have a reading of +12V.
P0002536

4000 - 34
Boom Section Valves
Ref # Description Connector # Wire Color Wire #
1 Left Fence Row J65 Red / White 159b

Black 55b
Brown 600
2 Ball Valve No. 1 J66 Red / White 159c
Black 55c
Red 601
3 Ball Valve No. 2 J67 Red / White 159d
Black 55d
Orange 602
4 Ball Valve No. 3 J68 Red / White 159e
Black 55e
Yellow 603
5 Ball Valve No. 4 J69 Red / White 153b
Black 55f
Green 604
6 Ball Valve No. 5 J70 Red / White 153c
Black 55g
Blue 605
7 Ball Valve No. 6 J71 Red / White 153d
Black 55h
Violet 606
8 Ball Valve No. 7 J72 Red / White 153e
Black 55k
Grey 607
9 Right Fence Row J73 Red / White 153f
Black 55m
White 608
NOTE: Test appropriate switches and wires.
Testing
• All boom section valves should have +12V from A to B with the key on.
• With the appropriate section switch on you should have +12V from C to B.
NOTE: Boom section valve connectors are located on the center section.

4000 - 35
P0002553

4000 - 36
Foamer
1. Foamer.
The following will each contain 1 White wire with a
Left/Right Liquid Foam (J61).

Left Air Foam (J63). 1
Right Air Foam (J64).
2
2. 6 Way Transorb.
Testing
• Actual voltage is less than 12V with foam P0002539
marker switch on. Should have 7-8V at full out-
put.
Service Brake Switch

1. Service Brake Switch (J319) contains 1 White
wire with a Red Stripe and 1 Orange wire.
NOTE: This switch is normally open during

operation.
Testing 1
• Should have +12V at A on the connector.
• With the brake applied, you should have +12V
on B.
P0002540
Ladder Down
1. Ladder Down (J306) contains 1 White wire with
a Red Stripe and 1 Green wire.
NOTE: This switch is normally open during

operation.
Testing 1
• Should have +12V between A / B and B / C.
P0002541

4000 - 37
Ballast Lamp
1. Ballast Lamp (J313) contains 1 Red wire with a
White Stripe and 1 Black wire.
1
NOTE: A is ground on this connector.
Testing
• Should have +12V on B when lamp is on.
NOTE: Replace ballast and lamp at same time.
P0002543
Front Work Lamps

The following will each contain 1 White wire with a Red
1. Left Work Lamp (J315).

Right Work Lamp (J317).
Testing 1
P0002544
Head Lights
The following will each contain 1 Yellow wire with a
Black Stripe, 1 Yellow and 1 Black wire.
1. Left Head Light (J314).

Right Head Light (J316).
Testing
P0002544

4000 - 38
Horn
1. Horn (J305) contains 1 Black wire with a White
Stripe and 1 Red wire.
NOTE: The horn switch supplies the ground on this

circuit.
1
Testing
• Should have +12V when horn is on.
• When the horn is off you should have a 0 Volts
reading. P0002545
Radar
1. Radar (J425) contains 2 White wires with a Red
Stripe, 1 Black and 1 Red wire.
Testing
• Should have +12V on C and D with black lead on A.
• B is required to have an H2 measurement, which
indicates movement. 1
P0002546
Auxiliary Boom Lights

The following will each contain 1 White wire with a Red
1
1. Left Auxiliary Boom Light (J426).
Right Auxiliary Boom Light (J426).
Testing
P0002548

4000 - 39
Tail Lights
The following will each contain 1 Red wire with a White
1. Left Rear Tail Light (J2).

Right Rear Tail Light (J3).
Neutral Wire (J406).
Testing
• Should have +12V on tail and brake lights.
P0002549
• With turn signal on, you should have a pulsing 12V.
Boom Pressure Sensor

NOTE: This is a Frequency Modulating Devise.
1. Boom Pressure Sensor (J91) contains 1 Red, 1

Green and 1 Black wire.
NOTE: The power is supplied by the liquid gauge set

(Fuse 56).
1
Testing
• Should have +12V on 3 with the black lead on 1.
• Pin 2 (the signal) requires special equipment to
monitor. P0002550
NOTE: A bad fuse on the liquid gauge set will result in sparge / boom failure, but still operates. Also, if the
sensor is not working the display will read 888.

4000 - 40
Boom Functions
Ref # Description Connector # Wire Color Wire #
1 Left/Hand Level Up J58 Violet / Black 715

Black 52t
2 Left/Hand Level Down J57 Violet 714
Black 52s
3 Left/Hand Inner Out J50 Red 721
Black 52h
4 Left/Hand Inner In J49 Red / Black 720
Black 52g
5 Right/Hand Outer Out J53 Green 710
Black 52n
6 Right/Hand Outer In J54 Green / Black 711
Black 52o
7 Right/Hand Level Down J60 Grey 717
Black 52w
8 Right/Hand Level Up J59 Grey / Black 716
Black 52v
9 Right/Hand Inner Out J48 Orange 719
Black 52f
10 Right/Hand Inner In J47 Orange / Black 718
Black 52e
11 Left/Hand Outer Out J51 Yellow 708
Black 52k
12 Left/Hand Outer In J52 Yellow / Black 709
Black 52m
NOTE: When testing for voltage, remove machine from neutral.
Testing
• All boom functions should have +12V when the appropriate function is on.

4000 - 41
Boom Functions
12
2
10
8
4
6
1
5
11
9
7
P0002554
Reverse Alarm
1. Reverse Alarm (J409) contains 1 Red wire with a
White Stripe and 1 Black wire.
Testing
• Should +12V only when in reverse. 1
NOTE: Reverse switch is located in the arm rest on the

FNR (Forward, Neutral and Reverse) lever.
P0002551

4000 - 42
Boom P.S.I. Switch
1. Boom P.S.I. Switch (J501) contains 1 White wire

with a Red Stripe and 1 Green wire.
• Boom P.S.I. Switch (J502) (Optional).
P0004157
Flow Meter
1. Flow Meter (J75) contains the following wires.

1 Red wire with a White Stripe.
1 Black.
1 Green wire with a White Stripe.
NOTE: When testing voltage use the ground in the

1
connector.
NOTE: Correct voltage problem before replacing the

flow meter.
P0002558
Hydraulic Filter Indicator

1. Hydraulic Filter Resistor (J411) contains 1 White
wire with a Red Stripe and 1 Green wire.
1
NOTE: This switch is normally closed during operation.

It is also part of the fail safe circuit.
Testing
• Should have +12V at the connector, when key is on.
• Filter is clogged or restricted.
P0002561

4000 - 43
Hydraulic Level
1. Hydraulic Oil Level/Temp. (J412) contains 1 Yellow
wire with a Red Stripe and 1 White wire with a Red
Stripe.
Testing
• Should have +12V at the connector, when key is on. 1
P0002561
Cab Harness 1
1. Connector (C88) - Power.
2. Connector (C89) - In/Out Interface.
6
3. Connector (C97) - Controller Interface.
4. Connector (C96) - Boom Shut-Off Senses.
5. Connector (C100) - SX Controller.
2
6. Connector (C106) - (If Equipped). 1
5
Testing: These connectors are interfacing wires
3
between the main cab harness and the application
harnesses. Reference schematic for appropriate
reading at these points, as they will vary depending on 4
application used.
P0002555
NOTE: The cab harness is located back and to the right
from the panel mount.
Cab Harness 2
1. Connector (C70/71) - Light Cluster.
2
2. Connector (C103) - Gauge Set Wires.
1
Testing: These connectors are interfacing wires
between the main cab harness and the application
harnesses. Reference schematic for appropriate
reading at these points, as they will vary depending on
application used.
NOTE: The cab harness is located close to the panel

mount.
P0002556

4001
Section 4001
STARTER MOTOR

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Starter Motor
4001 - 3
TABLE OF CONTENTS
NO LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Test Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Understanding No Load Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
STARTER SOLENOID TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Solenoid Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SPECIFICATIONS
No Load Test at 20°C (68°F)
Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 amperes maximum
Starter Drive Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4200 rpm minimum
LUBRICATION
Interval When the starter is disassembled or each time the engine is removed for repairs
Lubricant
Molukote-GN . . . . . . . . . . . . . . . . . . . . . . . . . . Use on shaft at pinion end of starter drive
Case Multipurpose Grease. . . . . . . . Use on bearings, gears, idler gear shaft and spring

4001 - 4
NO LOAD TEST
General Information
1. The no load test is done with the starter removed from the engine.
2. Check to see if you can pull the gear on the starter drive out of the starter drive housing.
3. Check to see if the starter drive can be turned. Pull the gear on the starter drive out of the starter drive
housing. Turn the gear in the clockwise direction to turn the starter drive and the armature. It should require
much force to turn. Turn the gear in the counterclockwise direction. It should turn with less force as the
clutch will be slipping.
4. If the starter drive cannot be turned, disassemble the starter and make repairs as needed. Then do the no
load test.
Test Equipment
The no load test can be done using a Sun Electric VAT-33 Tester, an equivalent tester, or separate pieces of
test equipment.
A hand held tachometer is needed to measure the speed of the armature shaft.
A remote starter button is needed to actuate the starter.
A fully charged 12 volt battery is needed to supply the electricity to turn the starter.
Test Procedure
The illustrations in this procedure show the use of the Sun
Electric VAT-33 Tester. Other test equipment can be used.
Connect the test equipment according to this procedure
and the manufacture’s instructions.
1
1. If the VAT-33 tester is being used:
A. Select the 0 to 100 ampere range. 3
B. Select the 18 to 40 volt range.
C. Move the volt lead switch to the EXT. Position.
2
D. Turn the load control to the OFF position.
2. Fasten the starter securely in a vise or use another 1. Positive Battery Cable 2. Battery Terminal
method to prevent the starter from moving during the 3. Negative Battery Cable
following test procedures.
3. Connect the positive battery cable to the battery ter-
minal on the starter solenoid and the negative battery 1
cable to the mounting flange on the starter.
4. Connect the positive load cable to the positive post of
the battery. Connect the negative load cable to the
negative post.
1. Positive Load Cable 2. Negative Load Cable

4001 - 5
5. Connect the red voltmeter lead to the motor terminal
on the starter solenoid.
1. Red Voltmeter Lead 2. Motor Terminal
6. Connect the black voltmeter lead to the mounting

flange on the starter.
1. Black Voltmeter Lead
7. Fasten the ammeter clamp around the positive bat-

tery cable so that the tip of the arrow is toward the
starter.
1. Ammeter

4001 - 6
8. Connect the leads from the remote starter button to
the battery and switch terminals.
IMPORTANT:The next three steps must be done rapidly.

Do not load the battery for more than 15 seconds at a
time. After the battery has been loaded for 15 seconds, let
the starter cool for 60 seconds.
1 2
1. Remote Starter Button 2. Switch Terminal

3. Battery Terminal
9. Actuate the remote starter button and turn the load

control until the voltmeter indicated 12 volts. 3
2
10. Look at the ammeter and make a record of the
ammeter reading.
11. Use the hand held tachometer and check the
armature shaft speed. Make a record of the shaft 4
speed.
12. Release the remote starter button and turn the load
control to the OFF position.
1. Remote Starter Button 2. Load Control

3. Voltmeter 4. Ammeter
5. Hand Held Tachometer

4001 - 7
Understanding No Load Results
1. If the current draw and the armature shaft speed are within the ranges under Specifications, the starter is
good.
2. Low armature shaft speed and high current draw are indications of too much friction. Possible causes of
too much friction are:
A. Tight, dirty or worn bearings.
B. A bent armature shaft.
C. Loose pole shoes (pole shoes make contact with the armature).
E. A short circuit in the armature coil. Disassemble the starter. Use an armature tester to check the
armature. Use the instructions included with the armature tester.
F. Damaged field coil.
3. If the armature does not rotate and the current draw is high, possible causes are:
A. Field terminal is making contact with the field frame. Inspect the insulators for the field terminal.
B. Damaged field coil.
C. Damaged bearings.
4. If the armature does not rotate and the current draw is zero, possible causes are:
A. An open field coil circuit. Disassemble the starter and inspect the field coil connections.
B. An open armature coil. Disassemble the starter and check for burned commutator bars. Use an
armature tester to check the armature. Use the instructions included with the armature tester.
C. Brushes are not making good contact with the commutator bars. Check for high insulation between the
commutator bars, broken brush springs, or worn brushes.
5. Low armature shaft speed and low current draw are indications of:
A. Dirt or corrosion on connections.
B. Damaged wiring.
C. Dirty commutator bars.
6. High armature shaft speed and high current draw are indications of a short circuit in the field coil. It is diffi-
cult to find a short circuit in a field coil. Install a new field coil. Do the no load test again to check for
improvement in the operation of the starter.

4001 - 8
STARTER SOLENOID TEST

This test will check the condition of the pull in winding and the hold in winding in the starter solenoid.
The jumper cable connected to the starter mounting flange and the motor terminal must have a common
connection at the negative battery post.
Solenoid Test Procedure

2
1. Remove the rubber boot, nut, lock washer and wire
from the motor terminal.
3
2. Connect a jumper cable to the positive battery post of
a fully charger 12 volt battery. Connect the other end
of the jumper cable to the battery terminal on the
starter solenoid housing. 5
3. Connect a jumper wire to the battery terminal and the
switch terminal on the starter solenoid housing. The
jumper wire must be made from No. 10 or larger
1
gauge wire. 4
4. Connect the jumper cable with the common
connection to the starter mounting flange and the
motor terminal in the starter solenoid housing. 1. 12 Volt Battery 2. Starter
3. Battery Terminal 4. Switch Terminal
NOTE: Steps 5 and 7 must be done in a maximum of 15 5. Motor Terminal
seconds to prevent damage to the pull in winding and the
hold in winding.
5. Connect the jumper cable with the common connection to the negative battery post. The pinion gear on the
starter drive must come all the way out rapidly and with force.
 WARNING: To prevent personal injury, stay clear of the pinion gear teeth while the starter motor is
running.
6. If the pinion gear did not come out as it should, the pull in winding is damaged. The complete starter sole-
noid housing assembly must be replaced.
7. Disconnect the jumper cable from the motor terminal in the starter solenoid housing. The pinion gear must
not move toward the starter drive housing.
8. If the pinion gear started to move toward the starter drive housing, the hold in winding is damaged. The
complete starter solenoid housing assembly must be replaced.

4002
Section 4002
BATTERY

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Battery
4002 - 3
TABLE OF CONTENTS
SAFETY RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ACCESS TO BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL AND INSTALLATION OF BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

To Remove Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
To Install Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOTE BATTERY TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspecting And Cleaning A Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BATTERY CONDITION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIFIC GRAVITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Temperature In Degrees Fahrenheit - oF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Temperature In Degrees Celsius - oC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Climate Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CAPACITY (LOAD) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Capacity (Load) Test Hook Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
THREE MINUTE CHARGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Three Minute Charge Test Hook Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Testing Battery Cells With Cadmium Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Test Procedure For 12 Volt Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BATTERY LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BATTERY FAST CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Fully Discharged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ACTIVATING CHARGED BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
NOTE: Case, LLC reserves the right to make improvements in design or changes in specifications at any time without
incurring any obligation to install them on units previously sold.
Spx 4260 Troubleshooting Manual

4002 - 4
SAFETY RULES
Before you service a battery, always wear face protection, protective gloves and protective clothing.
! Battery acid or battery explosion can cause serious injuries.
Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the
following:
• When you disconnect the battery cables, always disconnect the negative (-) battery cable first.
! • When you connect the battery cables, always connect the negative (-) cable last.
• Do not short circuit the battery posts with metal items.
• Do not weld, grind, or smoke near a battery.
BATTERY ACID CAUSES SEVERE BURNS. Batteries contain sulfuric acid. Avoid contact with skin,
eyes or clothing.
Antidote: EXTERNAL - Flush with water. INTERNAL - Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg or vegetable oil. Call physician immediately. EYES - Flush with
! water for 15 minutes and get prompt medical attention.
BATTERIES PRODUCE EXPLOSIVE GASES. Keep sparks, flame and cigarettes away. Ventilate
when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP
OUT OF REACH OF CHILDREN.
Battery explosion and/or damage to electrical components can result from improper connection of
! booster batteries or charger. Connect positive to positive and negative to negative. Externally, battery
acid can cause burns and blindness, and taken internally is poison.
When working around storage batteries, remember that all of the exposed metal parts are “live”. Never
! lay a metal object across the terminals because a spark or short circuit may result.
Connecting a battery charger or an auxiliary battery to a battery with an internal open circuit can cause
! a spark inside the battery. The spark can cause a battery explosion.

4002 - 5
SPECIFICATIONS
Battery Type: ............................................................................................. 12 Volt, Low Maintenance Type

Group Size 31
Rating: .................................................................................................................. 950 CCA at 0oF (-17oC)
Reserve Capacity: ................................................................................................................... 170 Minutes
Polarity:............................................................................................................................Negative Ground
NOTE: Two batteries are used in the SPX 4260.

4002 - 6
ACCESS TO BATTERIES
SPX 4260
The battery compartment is located on the RH side of

the machine. To service the batteries, pull down on the
latch (Item 1) on both sides.
Remove the cover.
P0002650P0
To Remove Batteries
1. Disconnect all ground cables from each battery nega-

tive (-) terminal.
2. Disconnect the positive cables from each battery pos-
itive (+) terminal.
3. Remove the battery hold down brackets (Item 1) to
remove the battery.
To Install Batteries
1
1. Be sure the carrier tray is clean and not damaged.
2. Install the battery in the correct position on the carrier.
P0002651
Tighten the hold down bracket (Item 1) securely.
3. Connect the positive cables to each battery positive (+) terminal in the reverse order of removal. Be sure all
cable and terminal connections are clean and tight.
4. Connect the ground cables to the negative (-) terminal of each battery in the reverse order of removal. Be
sure all cable and terminal connections are clean and tight.
NOTE: Apply Case Battery Saver or Urethane Seal

Coat to the cable terminals to prevent corrosion.
DO NOT use grease.

4002 - 7
REMOTE BATTERY TERMINALS

Remote battery terminals are located in front of the tool
storage box on the left side of the machine.
1
Positive (+) hook-up (Item 1).
Negative (-) hook-up (Item 2).
P0002652
BATTERY MAINTENANCE
Electrolyte Level
Check the level of the electrolyte in each cell every 250 hours of operation or once a month whichever
occurs first. The use of a large amount of water by the battery can be caused by high temperature during
hot weather or a voltage regulator setting that is too high.
Keep the electrolyte above the top of the separator plates at all times to prevent damage to the battery.
If the level of the electrolyte is low, add distilled water or other clean water until the electrolyte is just below
the split ring at the bottom of the cell opening. DO NOT OVERFILL. When water is added at ambient
temperatures below 32oF (0oC) the batteries must have a charge immediately to mix the water and
electrolyte.
NOTE: Add water only. DO NOT add electrolyte.
INSPECTING AND CLEANING A BATTERY

Visually inspect the batteries for dirt, corrosion and damage. Electrolyte and dirt on top of the battery can
cause the battery to discharge by making a passage for current to flow.
If damage causes an electrolyte leak, replace the battery.
If batteries must be cleaned, remove the battery from the carrier and clean the battery, cable terminals
and the carrier. Use Case Battery Saver and Cleaner (Part Number M20376) according to instructions on
the product container. This cleaner needs no water. If Case Battery Saver is not available, remove all
corrosion from the cable ends and battery terminals with a wire brush, then wash with a weak solution of
baking soda and water or ammonia and rinse with clear water. DO NOT permit any type of cleaner to enter
the cells of the battery.
Inspect the battery cables for damage. The positive battery cables must be inspected their entire length for
chaffing or other damage that may cause a short circuit. Replace any battery cable that has damage.

4002 - 8
BATTERY CONDITION CHECK

• The following procedure will tell if a battery is fit for service or if the battery must be replaced.
• Inspect the battery before testing. Many conditions can be seen and corrected before battery problems
occur.
• Inspect the battery case for cracks and leaks.
• Inspect the battery posts, cables and clamps for broken wires, loose connections and corrosion.
• Make sure the top of the battery is clean and dry. Dirt or electrolyte on top of a battery can cause the bat-
tery to discharge.
• Remove the filler caps (if equipped) from the battery. Check the vent holes in the filler caps and the vent
wells in the battery to make sure the vent holes are open.
• Check the battery carrier to make sure the carrier is in

good condition. Check battery brackets for the correct
tension. A loose battery bracket will allow the battery
to vibrate. Vibration will damage the battery. Battery
brackets which are too tight can buckle or crack the
battery case.
• Check battery for raised cell covers or a warped case.

This may indicate that the battery has been over-
heated or overcharged.
• Take a hydrometer reading of each battery cell, see

MS96B071
Specific Gravity Check.
NOTE: If the electrolyte level is too low to make a reading, add water to the battery cells. Then apply a fast
charge for 15 minutes. Then, take a hydrometer reading of each battery cell.
SPECIFIC GRAVITY CHECK

A hydrometer is used to make a test of the electrolyte in the
battery. The test will indicate the specific gravity (weight) of the
electrolyte. The specific gravity (weight) of the electrolyte tells the
approximate level of charge in each cell of the battery.
NOTE: If water has been added to the battery, the hydrometer

reading will be false. Apply a fast charge for 15 minutes.
Then take a hydrometer reading of each battery cell.
Hydrometers are calibrated to give the correct reading when the
temperature of the electrolyte is 80oF (27oC).
Some hydrometers include a thermometer. If your hydrometer does
not include a thermometer, a separate thermometer will be required
to take the temperature of the electrolyte.
When using a hydrometer, always remove enough electrolyte from a
battery cell to allow the float in the hydrometer to float freely. Check
MS96B072
float reading at eye level, making sure float does not make contact
with the glass. Write the float reading for each battery cell on a piece of paper.
Compare float reading with electrolyte temperature.
4002 - 9
Temperature In Degrees Fahrenheit - oF

• Electrolyte temperature above 80oF. Add 4 points (.004) to the float reading for each 10o above 80oF.
• Electrolyte temperature below 80oF. Subtract 4 points (.004) from the float reading for each 10o below
80oF.
Temperature In Degrees Celsius - oC

• Electrolyte temperature above 27oC. Add 4 points (.004) to the float reading for each 6o above 27oC.
• Electrolyte temperature below 27oC. Subtract 4 points (.004) from the float reading for each 6o below 27oC.
NOTE: The correct float reading is the specific gravity (weight) of the electrolyte in the battery.
NOTE: Compare the corrected float readings with the following chart. This will tell you the charge rate in the
battery.
Battery Specific Gravity Range For

Charge Climate Zone
% (Reading corrected to 80°F or 27°C)
Frigid Temperate Tropical
100% 1.270 1.250 1.225
75% 1.230 1.215 1.180
50% 1.180 1.170 1.135
25% 1.130 1.120 1.090
Discharged 1.080 1.070 1.045 MS96B073
If the readings are close to the 75% battery charge figures, the battery is probably satisfactory. Charge the
battery and make the Capacity Test.
If the readings are close to the 100% battery charge figures, make the Capacity Test to check for internal
problems.
If the readings are over the 100% battery charge figure, the battery is overcharged. Check the charging system
regulator.

4002 - 10
CAPACITY (LOAD) TEST

The capacity of a battery is the ability to give current and maintain voltage. If the battery passes the
capacity test, the battery is in satisfactory condition. However, the battery may need additional charging.
When a battery is cold, below 80oF (27oC), the battery can have a lower discharge capacity. If a cold
battery fails the capacity test, let the battery stand until the temperature reaches 80oF (27oC). Then test
the battery again.
Procedure
1. Turn the load control knob on the tester to the OFF position.
2. Turn the voltage switch on the tester to 16 volts for a 12 volt battery.
3. Connect the tester wires as shown:
Red clips to battery positive post.
Black clips to battery negative post.
NOTE: The wire clips from the volt meter side of the tester must contact the battery posts.
4. Turn the load control knob clockwise until the ampere hour rating of the battery is reached. If the tester is
not equipped with an ampere hour rating scale, set the load control at three times the ampere hour rating
of the battery.
EXAMPLE: 180 amperes for a 60 ampere hour battery.
NOTE: If the battery being tested has been made for use in high temperature climates, set the load control at
two and a half times the ampere hour rating of the battery.
5. Only apply the load on the battery for 15 seconds. Check volt meter figure and turn load control counter-
clockwise to the OFF position.
If the volt meter reading was in the green band or at least 9.6 volts for a 12 volt battery, the battery has
good output capacity. Test the specific gravity of the battery and charge if necessary before putting in
service.
If the volt meter reading varied by more than 0.1 volts, the battery has one or more defective cells.
If the volt meter reading was below 9.6 volts for a 12 volt battery, do the Three Minute Charge Test to see if the
battery is discharged or defective.
CAPACITY (LOAD) TEST HOOK UP
MS96B074

4002 - 11
THREE MINUTE CHARGE TEST

Make this test on batteries that have not passed the Capacity Test.
1. Turn the volt meter selector switch to 16 volts for a 12 volt battery.
2. Connect the tester wires as shown:
Red clips to battery positive (+) post.
Black clips to battery negative (-) post.
NOTE: The wire clips from the volt meter side of the tester must contact the battery posts.
3. Turn the battery charger on.

4. Turn the battery charger time switch past 3 minutes and then back to 3 minutes.
5. Adjust the charging switch to the highest rate without exceeding 40 amperes for a 12 volt battery.
6. When the time switch on the battery charger returns to slow charge, after 3 minutes, reset the time switch
to fast charge.
7. Check the volt meter reading while the battery charger is on fast charge.
If the volt meter reading is above the green band or exceeds 15.5 volts on a 12 volt battery, replace the battery
since the battery is worn out or sulfated.
If the volt meter reading was in the green band or at least 15.5 volts for a 12 volt battery, go the next step.
8. Check each cell voltage. If the battery has connecting straps across the cells, go to Step 9. If the battery
does not have connecting straps across the cells, see Testing Battery Cells with Cadmium Probes.
9. With the battery charger operating on fast charge, set the volt meter switch to 4 volts. With a fast move-
ment, measure the cell voltage across each cell by putting volt meter clips on each connecting strap.
If the volt meter readings vary more than 0.1 volts between the cells, replace the battery.
If the volt meter readings were within 0.1 volts of each other, battery is discharged. Test specific gravity
and charge as necessary.
MS96B075

4002 - 12
TESTING BATTERY CELLS WITH CADMIUM PROBES

The cadmium probes are used with a Battery Starter Tester and a Volt Meter. The cadmium probes check
cell voltage on batteries with hard covers.
Disconnect the wire leads from the volt meter. Check the volt meter gauge, the gauge needle must be on
zero. Adjust the gauge needle if necessary.
Connect the wire leads to the cadmium probes and to the volt meter.
Set the volt meter to the 0 to 4 volt range. Remove the vent/fill caps from the battery.
The following test procedure will indicate the cells by number. The cell at the positive terminal end of the
battery is number 1.
1. Put the positive probe in cell number 1 and the negative probe in cell number 2.
NOTE: After each test, write the volt meter gauge reading on a piece of paper. The readings from one cell to
another must be compared after all tests are made.
2. Place the positive probe in cell number 2 and the negative probe in cell number 3.
6. Place the positive probe on the positive terminal post of the battery and the negative probe in
cell number 1.
7. Place the positive probe in cell number 6 and the negative probe on the negative terminal post of the
battery.
If the gauge needle on the volt meter reads to the right of zero, add this reading to the reading in Step 6.
If the gauge needle on the volt meter reads to the left of zero, go to Step 8.
8. Place the positive probe on the negative terminal post of the battery and the negative probe in
cell number 6. Subtract this reading from the reading in Step 6.
Compare all the readings with each other. If the readings are more than 0.1 volt between any step, replace
the battery.

4002 - 13
TEST PROCEDURE FOR 12 VOLT BATTERY
MS96B076

4002 - 14
BATTERY LEAKAGE TEST

Electrolyte, dirt, water, etc. on the top of a battery will cause the battery to discharge. This material on the top
of a battery gives a path for current to flow, permitting the battery to discharge.
1. Turn the voltage switch on the tester to the 4 volt position.

2. Connect the negative wire of the volt meter to the negative post on the battery.
3. Move the positive wire of the volt meter around the surface of the battery. When moving the positive wire
around the battery, do not contact the positive post cell connector straps with the positive wire.
4. Check the volt meter for needle movement.
If the gauge needle indicated movement, the battery has foreign material on the case. When this condition
is present, remove the battery from the vehicle. Clean the outside of the battery. Also clean the battery
tray. When cleaning a battery, use a solution of baking soda or ammonia and water. Check and clean the
battery cables if necessary.
MS96B077

4002 - 15
BATTERY FAST CHARGING

IMPORTANT: Before fast charging a battery, always test the battery. DO NOT fast charge a battery
that has not passed the Three Minute Charge Test.
Find the specific gravity reading of the battery in the Fast Charge Time Table. The time table will give you the
maximum period of time that the battery can be fast charged. Set the rate of charge on the battery charger so
that the voltage is not more than 15.5 volts for a 12 volt battery.
IMPORTANT: Always disconnect the battery cables, before fast charging the battery. Fast charging a
battery with the cables connected will damage the regulator.
Always allow fast charging a battery with a period of time of slow charging. Slow charge the battery until the
specific gravity reading of the electrolyte indicates the battery is fully charged.
FAST CHARGE TIME TABLE

SPECIFIC GRAVITY TIME TABLE FOR CLIMATE ZONE CAN BE FAST
Readings corrected to 80oF (27oC) CHARGED UP TO:
FRIGID TEMPERATE TROPICAL
1.150 or less 1.135 or less 1.110 or less 1 hour
1.150 - 1.175 1.135 - 1.160 1.110 - 1.130 3/4 hour
1.175 - 1.200 1.170 - 1.185 1.130 - 1.150 1/2 hour
1.200 - 1.225 1.185 - 1.210 1.150 - 1.170 1/4 hour
Above 1.225 Above 1.210 Above 1.170 Slow Charge

4002 - 16
BATTERY CHARGING
Check and correct the electrolyte level in the battery before charging the battery.
Charging rates in the 5 to 50 ampere range are acceptable. It is difficult to give an exact charging rate or
time because of:
• Ampere hour rating on batteries vary.

• The temperature of the electrolyte in the battery.
• Current stage of charge the battery is in.
• The age and condition of the battery.
See the chart on this page for charging rates and times for a fully discharged battery.
The battery can be charged at any ampere rate, shown in the chart, as long as the electrolyte in the battery
does not boil over or the temperature does not go over 125oF (52oC). If the electrolyte in the battery boils over
or the temperature goes over 125oF (52oC), the charging rate must be decreased or stopped to prevent
damage to the battery.
A battery will be fully charged, when after a two hour period the following conditions occur:
• All battery cells are gassing freely (not boiling over)

• No change in the specific gravity of the electrolyte
• Specific gravity of the electrolyte is approximately 1.260
Fill each battery cell with electrolyte until the level of the electrolyte is even with the split ring at the bottom of
each cell opening.
FULLY DISCHARGED BATTERIES
Ampere Hour Recommended Rate and Time
Rating
5 Amperes 10 Amperes 20 Amperes 30 Amperes 40 Amperes 50 Amperes
50 or less 10 hours 5 hours 2-1/2 hours 2 hours
50 to 75 15 hours 7-1/2 hours 3-1/4 hours 2-1/2 hours 2 hours 1-1/2 hours
75 to 100 20 hours 10 hours 5 hours 3 hours 2-1/2 hours 2 hours
100 to 150 30 hours 15 hours 7-1/2 hours 5 hours 3-1/2 hours 3 hours
Above 150 20 hours 10 hours 6-1/2 hours 5 hours 4 hours
NOTE: Ampere rating above indicates the initial rate of charge for a constant voltage taper rate battery
charger.

4002 - 17
ACTIVATING CHARGED BATTERIES

To activate a dry charged battery fill each battery cell with electrolyte (a solution of sulfuric acid and water) that
has a specific gravity reading of 1.260. Fill each battery cell until the level of the electrolyte is even with the split
ring at the bottom of each cell opening.
Let the battery set for 10 minutes, then check the level of the electrolyte in each battery cell. Add
additional electrolyte to the battery cells if necessary, DO NOT add water. Adding water to the battery cell
will give you a battery with bad performance and a short life.
Before putting the battery into service, make the following tests:
• Five minutes after adding electrolyte, check the terminal voltage of the battery. If the voltage is less than 10
volts on a 12 volt battery, there is a defect in the battery and the battery must be replaced.
• Check the specific gravity of the electrolyte. If the reading on the specific gravity indicates a decrease of 30
or more points on one or more cells in the battery, the battery must be put on a battery charger and fully
charged.

4003
Section 4003
ALTERNATOR

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Alternator
4003 - 3
TABLE OF CONTENTS
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
HOW IT WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
SAFE METHODS TO BE USED WHEN MAKING REPAIRS ON ALTERNATOR SYSTEM .5
TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
CHARGING SYSTEMS CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Batteries Not Charging Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
CHECKING ALTERNATOR OUTPUT ON BENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

4003 - 4
SPECIFICATIONS
Output .............................................................................................................................14 volts at 135 amperes
Resistance of rotor winding...................................................................................................... 2.60 ± 0.26 ohms
Resistance of stator winding ................................................................................................ 0.053 to 0.058 ohms
Minimum brush length.................................................................................................................. 5 mm (0.2 inch)
SPECIAL TORQUES
Alternator Mounting Nuts and Bolts ........................................................................................... 74 lb ft (100 Nm)
Pulley Retaining Nut................................................................................................... 44 to 52 lb ft (60 to 70 Nm)
Alternator Mounting Screw................................................................................................. 3 to 4 lb ft (4 to 5 Nm)
SPECIAL TOOLS
CAS-10344 CHARGING SYSTEM ANALYZER
NOT SHOWN
OEM-1053 BATTERY LOAD TESTER
NOT SHOWN
CAS-10748 ALTERNATOR/GENERATOR TESTER
28410
HOW IT WORKS
The charging system consists of a alternator with a built in
regulator (Item 3). A 39 ohm load circuit (Item 1) is
housed within the instrument cluster. Current flows from
the positive posts of the batteries (Item 2) through the
jump start stud to the starter solenoid. When the key 2
switch is in start and run positions current flows from the 1
instrument cluster to the alternator. Terminal D+ is used to
excite the field windings and start the alternator charging.
If the system voltage, measured at the instrument cluster
is 16 volts or higher, a battery voltage fault icon will be
displayed on the instrument cluster. If the alternator signal
is more than 4 volts below the system voltage, the battery
voltage fault icon will be displayed on the instrument
cluster.
When the alternator is operating, AC voltage is generated 3

in the stator coils. The diodes in the rectifier bridge MA99D002
change this AC voltage to a DC voltage. This DC voltage
is available at the alternator B+ terminal. This DC voltage
and current also flows through the exciter diodes to the voltage regulator and to the field coil. This extra flow of
current to the field coil makes the magnetic field stronger which increases the alternator output.
As the speed of the alternator increases, current is generated for charging the battery and for operating the
electrical accessories. With the alternator running, the voltage is the same at the B+ terminal on the alternator
as the D+ terminal on the voltage regulator.

4003 - 5
SAFE METHODS TO BE USED WHEN MAKING REPAIRS ON

ALTERNATOR SYSTEM
Do not clean the alternator with a solvent or steam. This can cause damage to the internal parts of the
alternator.
Do not let any oil enter into the ventilation openings of the alternator when doing service to the engine. This
can prevent the alternator from charging.
Always turn the key switch to OFF position and disconnect the battery ground cables when working on the
alternator or before arc welding on the tractor or connected implement.
Make an inspection of the terminals, connectors and wires at regular intervals. Check the terminals and the
connectors for loose connections and corrosion. Make sure that there is no damage on the insulation of the
alternator wires. These conditions can cause the voltage to be lower than the correct battery voltage and cause
the alternator to generate more current than is correctly needed to charge the battery.
Make sure that the mounting bolts for the alternator are tight. Check the belt for correct alignment, correct
tension and more than normal wear. These conditions can cause the belt to slide on the alternator pulley.
TEST PROCEDURES
For the best accuracy, test the alternator system with all of the system parts still installed on the tractor. Before
testing the system, check the following:
1. Battery - The battery must be at least 75% fully charged and the battery voltage must be at least 12 volts.
2. Connections - Make sure that all the connections on the alternator system components are clean and do
not have too much corrosion. Too much corrosion on terminals and connectors will cause a loss of battery
voltage to the voltage regulator.
3. Drive Belts - Make sure that the drive belts are tight and do not have any grease or oil on the contact
surfaces that can cause the belts to slip.

4003 - 6
CHARGING SYSTEMS CHECKS

Batteries Not Charging Correctly
2
System Check (Method One)
1
2
1. Make sure the batteries are fully charged. Connect 3
1
the charging system analyzer to the alternator, see 4
Special Tools page. Connect the red lead to the
battery B+ (Item 1) terminal on the alternator.
Connect the black lead to the alternator housing
T94114
(Item 2).
2. With the engine stopped, the key switch in the OFF

position and the light switch in the ROAD position, 3
check the lamps on the analyzer. The No. 2 lamp illu-
minated indicates good batteries. If the No. 2 and No.
4 lamps are both illuminated, check for a bad cell in
the batteries.
1
2
3. Run the engine at rated speed. Turn the light switch to 3
the ROAD position. Wait for the charging system to 4
become stable and check the indicator lamps on the
analyzer. If no lamps are illuminated the charging
system is normal. If lamp No. 1 is illuminated replace
the voltage regulator. If lamp No. 2 or No. 2 and No. 4 T94116
are illuminated, see part C below. If lamp No. 3 or No.
2 and No. 3 are illuminated, disassemble the alternator and check the components.
4. If the test in part B above shows the charging system to be normal, and the alternator service indicator is
illuminated, move the red lead to the D+ terminal (Item 3) on the alternator. Run the engine at rated speed
and turn the light switch to the ROAD position. If the No. 3 indicator lamp is illuminated, replace the rectifier
bridge.
System Check (Method Two)
1. Make sure that the batteries are fully charged and that
all wiring harness leads are connected. Turn all 2
accessories OFF.
1
2. Connect the positive lead from the voltmeter to the B+
terminal (Item 1) on the alternator. Connect the nega-
tive lead from the voltmeter to the alternator housing
(ground) (Item 2). If the reading on the voltmeter is
lower than battery voltage or has a zero reading,
check and make repairs to the wiring between the B+
terminal (Item 1) of the alternator and the batteries. T94117

4003 - 7
3. Connect the positive lead from the voltmeter to the D+
terminal (Item 3). Connect the negative lead from the
voltmeter to the alternator housing (ground) (Item 2). 2
3
If the reading on the voltmeter is zero.
T94271
NOTE: Use heavy gauge wire for all connections.
4. Run the engine at rated speed. Check to make sure

that all accessories are turned OFF. Connect the 8
positive lead of the voltmeter to the positive stud 7
(Item 4) on the battery. Connect the negative lead of
the voltmeter to the negative terminal (Item 5) of the 4
battery. If the reading on the voltmeter is 15 volts or
more, disassemble the alternator and check the
components.
5. Disconnect the battery negative cables from the

negative terminal on the starter. Connect an ammeter
(Item 6) in the circuit at the B+ terminal (Item 7) of the 6
alternator. Connect the battery negative cables to the 5
negative terminal on the starter. Turn the light switch
MA99D003
to the ROAD position and connect a battery load
tester (Item 8) (see Special Tools page) across the
battery terminals (Item 4)(Item 5). Run the engine at rated speed and adjust the battery load tester for
maximum current output.
NOTE: If the reading on the ammeter is between 135 and 145 amperes and the alternator service monitor is
illuminated, disassemble the alternator and test the rectifier bridge.

4003 - 8
CHECKING ALTERNATOR OUTPUT ON BENCH

Install the alternator onto an alternator-generator tester. Follow the instructions supplied with the tester for
testing the alternator.
When an alternator-generator tester is not available, but a variable speed source is available, connect the
equipment as shown to the alternator and a fully charged battery. Do not connect the battery load tester across
the battery at this time.
1. Apply rotation to the alternator shaft and slowly

increase the shaft RPM. The reading on the voltmeter 4
will increase with speed, but must not increase
beyond 15 volts at maximum speed. If the voltage
increases beyond 15 volts, check to make sure that
there is not an electrical connection between the slip 5
rings and ground. Test the voltage regulator and
replace if bad before continuing to part 2 below.
2. If voltage in part 1 is less than 15 volts, connect the
carbon pile across the battery. Operate the alternator
at 5000 RPM and increase the load on the carbon pile
until the alternator shows maximum output on the
ammeter. The amperage read on the ammeter must
not be less than 130 amperes.
NOTE: Use heavy gauge wire for all connections. 2 3
6 7
1
24810
Item Numbers
1. Ammeter
2. 12 Volt Battery
3. 10 OHM 8.5 Watt Register
4. Ammeter
5. Battery Load Tester
6. B+ Terminal
7. D+ Terminal

5000
Section 5000
HYDRAULIC SYSTEM

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Hydraulic System
5000 - 3
TABLE OF CONTENTS
HYDRAULIC DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
High Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Parking Brake Quick Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Charge Pressure Test Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Access Ladder Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Wheel Motor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Pressure Limiter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
PCP Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Product Pump Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3 Section Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Manifold Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Park Brake Valve Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inner Boom Fold Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Boom Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Outer Boom Fold Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Active Suspension Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Boom Height Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Neutral Shunt Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6 Section Valve Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Hydrostatic Pump Neutral Adjustment (Not pictured). . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
HYDRAULIC SCHEMATIC SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Quick Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HYDRAULIC SCHEMATICS AND DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Open Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Closed Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Drop Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Hydraulic Component Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
90 Series Pump SPX 4260. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
51 Series Wheel Motors SPX 4260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
90 Series to the 51 Series SPX 4260. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
PCP / Servo to Components SPX 4260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Auxiliary Components SPX 4260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Product Pump Control Valve SPX 4260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Boom Fold Circuit SPX 4260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Return to the Tank SPX 4260. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pump Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Aeration of Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SX CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Propel Handle Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Neutral Safety Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reverse Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rotary Position Sensor Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Controller Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5000 - 4
Clearing Calibration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SX Error Code / Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5000 - 5
HYDRAULIC DIAGNOSTICS
NOTE: This pressure should be less than that specified on the hydraulic schematic, otherwise the cooler is in
bypass. This will not allow any oil flow across the cooler, thus no reduction in the temperature of the oil.
NOTE: These procedures are intended to assist the technician in diagnosing a hydraulic problem. Not every
safety or precautionary measure is listed. Use proper care and consideration when performing any of the
above procedures.
NOTE: As with any hydraulic work, cleanliness is of utmost importance. Proper cleaning of the area before and
after service is necessary. Any components repaired or replaced must also be thoroughly cleaned.
NOTE: Any hydraulic connections taken apart must be properly capped and plugged. Care must also be given
until a hydraulic circuit is properly bled of all air that may be trapped in the system.
High Pressure Test

M2 Forward M1 Forward
IMPORTANT: When testing full system pressure, a
second person is required in the cab to operate the
service brake, anchoring the machine and turn the
machine off if needed.
NOTE: When testing the system pressure on the

hydrostatic loop, 10,000 psi gauges are necessary.
1. Disconnect parking brake quick connect.

2. For checking forward loop pressure, 10,000 psi M1 Reverse M2 Reverse
gauges must be installed on port M2 of the left hand
hydrostatic pump and on M1of the right hand hydro- P0002645-2
static pump. Quick connections are installed on each
of the pumps for your convenience.
3. Start the engine and warm the hydraulic oil to a minimum of 120 degrees F.
4. Increase the engine RPM to normal operating speed
5. Disengage the parking brake lever located on the lower left corner of the operator's seat.
6. Move the hydrostatic control lever forward, as if to propel the unit in a forward motion.
7. Have a second individual observe what pressures are attained on both hydraulic gauges.
8. After reading is taken, return hydrostatic lever to the neutral position and return throttle to low idle.
9. When checking the reverse loop pressure, install the 10,000 psi gauges on port M1 of the left hand hydro-
static pump and on M2 of the right hand hydrostatic pump (Quick connects are provided on these ports).
10. Follow the above stated procedures, but move the hydrostatic control handle rearward, as if to propel the
unit in reverse.
Refer to the hydrostatic pump nameplate model code for the correct pressures on both forward and reverse
side pressure loops. In the stalled condition described above, the gauge readings should exceed listed
pressures. System pressure is referenced to charge pressure, so the above stated number is the difference
between the high and low side system pressure loops.
Any adjustments required to raise or lower the pressure limiter setting are accomplished by rotating the
pressure adjustment screw located on the multifunction valve.
As both pumps forward loops are connected with a hydraulic hose, to truly separate the loops from sharing oil,
the traction assist must be activated.
Activate the traction assist by depressing the foot pedal located on the front right corner of the operator's seat.
Depressing this lever activates an electrical solenoid, which blocks the shared oil passage and allows a true
pressure reading for each individual pump.

5000 - 6
Parking Brake Quick Disconnect
This component is located behind the right hand front axle
tube. It is used primarily as a troubleshooting aid when
testing certain hydraulic components. By disconnecting
the fitting (1), no oil is supplied to the planetary drive hubs
allowing the internal parking brakes to be remain
released.
P0002647
Charge Pressure Test Port

The test ports provided to check or verify charge pressure
on the hydrostatic systems are located on the external
filter head of each hydrostatic pump. There are two ports
on each filter head. To correctly measure charge
pressure, the gauge must be installed in the “after filter”
port. These ports are closest to the case of the pump.
1. To correctly measure charge pressure, the hydraulic

oil should be at a minimum of 120 degrees F.
2. Install either a 600 or 1000 psi gauge on port M3
(after filter) of each hydrostatic pump. The right hand
pump is equipped with a quick connect, while the left
hand pump has a JIC fitting provided which can be P0002653
accessed by removing the cap.
3. Remove one end of the hydraulic hose (1) connecting
the two “before filter” ports on the filter heads. Install a
plug in the hose, then cap the filter head fitting. This
process eliminates the sharing of pre-filtered oil
between the two charge pressure loops and will show 1
only that particular pump's true charge pressure.
4. Start the engine, then set the engine rpm level to
approximately 1300 rpm (This setting is required for
proper pump rpm). The gear increaser is the reason
for the rpm difference between the engine and
hydrostatic pumps. The gear increaser is located
between the engine and hydrostatic pumps.
NOTE: This is a 1.38:1 gear increaser. Divide 1775 pump P0003160

rpm by 1.38 to arrive at the 1300 engine rpm.
5. Record the reading on the gauge. Reference the hydrostatic pump name plate mode code for the correct
pressure setting.
6. Charge pressure is referenced to case pressure. To correctly set charge pressure, install a 100 psi
pressure gauge in port L2 of the hydrostatic pump to determine the case pressure developed on each
pump. The gauge reading from port L2 should be added to the factory setting as listed on the model code
found on the pump name plate.
NOTE: The total of these two numbers should be the recorded gauge pressure.
7. Any adjustments necessary are accomplished by loosening the lock nut and rotating the charge pressure
relief valve to attain the desired setting. Once the desired setting is achieved, tighten the lock nut.

5000 - 7
Access Ladder Cylinder
• The pressure to the access ladder cylinder is supplied by
charge pressure oil. The tie point for the pressure hose
attached to the blind end of the cylinder comes from the
downstream side of the park brake valve manifold. When
the park brake is disengaged, the charge pressure oil is
allowed to the blind end of the cylinder and extends the
rod, raising the ladder. The rod end of the cylinder is
drained off to the hydraulic reservoir.
• A.042” diameter orifice is installed at the blind end of the
cylinder to create a pressure drop and slow down the
speed at which the ladder is raised. P0003178
• If you have a low charge pressure reading and have veri-
fied that all wheel motor case drains are within specifications, plug or cap the supply line to the ladder fold
cylinder to verify the integrity of the seal within the cylinder.
NOTE: A faulty seal will allow charge pressure oil past the seal and thereby be drained back to the hydraulic
reservoir.
Wheel Motor Tests

Loop Flushing
Flow
IMPORTANT: When testing full system pressure, a second
person is required in the cab to operate the service brake,
anchoring the machine and turn the machine off if needed.
1
Loop flushing is a vital function of a closed loop hydraulic system.
It is responsible for cooling and cleaning of the hydrostatic system 2
by intentionally bleeding off a certain amount of oil. This process
removes some of the hot oil, as well as contaminants, from the
P0002656
system. The oil removed from the system is replaced by the
charge pump within the Series 90 hydrostatic pump.
NOTE: In a normally functioning unit, a 0-5 gallon per minute flow meter will be necessary for testing.
1. Install the flow meter in the case drain line (1) from the wheel motor to the hydraulic oil reservoir. Make
sure that the direction of flow indicated on the meter is consistent with the true oil flow path.
2. Disconnect the parking brake quick coupler (See Section No. 3).
3. Start the unit and raise the hydraulic oil temperature to a minimum of 120 degrees F.
4. Increase the engine rpm level to the normal operating range and push the hydrostatic control lever forward.
5. Record the reading from the flow meter (1st Reading).
6. Return the hydrostatic control lever to neutral and return the engine to low idle. Shut the unit down (place
key in the off position).
7. Next, install the flush defeat spool (2) (part number 312713) and caps (part number 312714) in place of the
factory installed loop flushing valve. Reference the Sauer-Danfoss literature for the correct procedure and
torque values.
8. Start the unit and increase the engine rpm level to the normal operating range and push the hydrostatic
control lever forward.
9. Record the reading from the flow meter (2nd Reading).
10. Return the hydrostatic control lever to neutral and return the engine to low idle. Shut the unit down (key off).
11. Subtract the second reading from the first recorded reading. This will give you the true loop flushing gallons
per minute (Reference the correct hydraulic schematic to determine the required pressure reading).
NOTE: If the unit has excessive case leakage from any wheel motor being tested, it is possible for the 0-5
gallon per minute flow meter to be undersized.
5000 - 8
Case Drain
This test is to confirm whether or not there is excessive case leakage from the motor resulting in a low charge
pressure reading on the hydrostatic pump(s).
NOTE: In a normally functioning unit, a 0-5 gallon per minute flow meter will be necessary.
1. This flow meter is to be installed in the case drain line from the wheel motor to the hydraulic oil reservoir.
Ensure that the direction of flow indicated on the meter is consistent with the true oil flow path.
2. Disconnect the parking brake quick coupler.
3. Install the flush defeat spool (part number 312713) and caps (part number 312714) in place of the factory
installed loop flushing valve. (Reference the Sauer-Danfoss literature for the correct procedure and torque
values.)
4. Start the unit and raise the hydraulic oil temperature to a minimum of 120 degrees F.
5. Increase the engine rpm level to the normal operating range and push the hydrostatic control lever forward.
6. Record the reading from the flow meter.
7. Return the hydrostatic control lever to neutral and return the engine to low idle. Shut the unit down (key off).
8. The recorded reading is the true case leakage from that motor. All intentional leakage has been eliminated
by installing the flush defeat spool.
Control Start Points (Threshold)-Wheel Motor shifting
This test is to determine at what input (signal) pressure the wheel motor starts shifting from maximum
displacement towards minimum displacement.
NOTE: In a normally functioning unit, all four motors start to shift at the same input pressure.
Test equipment needed for the following test:

1 - 600 psi gauge.
1 - 10,000 psi gauge.
2
1. Install the 600 psi gauge in the M7 port (1) or install a

tee fitting in the X1 port and then connect the pres-
sure gauge to the tee fitting.
2. Remove the existing plug fitting located in the M3 port
(2) of the wheel motor and install a test fitting. Con- 1
nect the 10,000 psi gauge to this fitting.
4. Start the unit and warm the hydraulic oil to a minimum
of 120 degrees F. P0002656
5. Rotate the speed control knob clockwise to approxi-
mately one half of it's travel.
6. Increase the engine rpm level to the normal operating range.
7. Gradually move the hydrostatic control lever out of neutral as if to propel the unit in a forward motion. While
this is transpiring, a second individual is required to monitor the pressure gauges installed on the unit.
8. As the hydrostatic control lever is moving forward, the pressure reading on the gauge installed in the
M7/X1 port should gradually rise. While this pressure continues to rise, monitor the pressure on the gauge
installed in the M3 port. Once this gauge rapidly jumps in pressure, record the input (signal) pressure indi-
cated on the gauge installed in the M7/X1 port. This pressure should equal the factory set pressure as indi-
cated on the motor nameplate as found in the model code of that motor.
9. If the signal pressures on all four motors do not equal each other, adjustments must be made to the wheel
motors considered to be out of specification. Reference the Sauer-Danfoss Technical, Service, and Repair
Manuals for the correct adjustment procedure.

5000 - 9
Pressure Limiter Valve
• The pressure limiter valve has two separate design
intents. The first being an engine protection device
during a rapid deceleration, the second allowing full
torque/flow when the hydrostatic control lever is
moved to the reverse position.
• If a unit experiences sluggish performance when
placed in reverse, an issue with the pressure limiter
valve may exist. This is mostly noticed with a full prod-
uct tank and soft ground conditions.
• When the hydrostatic control handle is in the neutral
or forward position, the valve is in it's normally open
state. Once the input pressure (coming from the P0003164
reverse side high pressure loop) exceeds the spring
setting, the valve opens allowing this higher pressure oil to act on the opposite side of the servo in the
hydrostatic pump, slowing down the rate at which the pump destrokes. This keeps the engine rpm level
from increasing during a rapid deceleration.
1 - 0-5 Gallon Per Minute Flow Meter.
NOTE: The following test will require two people. 1 to operate controls in cab, while the other is recording
gauge readings.
1. Install the flow meter between the outlet side of the pressure limiter valve and the input to the servo ports
(M4 or M5) on the hydrostatic pump.
2. Disconnect the parking brake quick coupler (See Section No. 3).
4. While the person in the cab increases the engine rpm level to the normal operating range, and places the
hydrostatic control lever in the reverse position.
5. The second person is recording the gauge readings on the flow meter.
NOTE: With a properly functioning component, there should be zero (0) oil flow recorded.
PCP Valve
IMPORTANT: When testing full system pressure, a second person is required in the cab to operate the service
brake, anchoring the machine and turn the machine off if needed.
NOTE: Testing of the PCP valve is not only a hydraulic test, but an electrical check as well.
1 - Test Breakout Harness.

2 - 600 P.S.I. Pressure Gauges.
2 - Digital Multi-Meters.
NOTE: The test breakout harness can be obtained through the service department. This harness should be a
four pin Packard connection with the wire running from the “A” pin of one connector to the “A” pin of the
opposing connector severed and test sleeves installed.
NOTE: This connector greatly increases effectiveness.

5000 - 10
PCP Valve (Cont’d)
NOTE: The same procedure should be done on the wire running from pin “C” on one connector to pin “C” of
the opposing connector.
1. Install a digital multi-meter in the wires for pin “A”. Set the digital multi-meter to milliamps, record the
current supplied from the SX Control to one coil inside the PCP valve. Install a second digital multi-meter in
the wires for pin “C” to record the current supplied to the second coil inside the PCP valve.
2. Install one 600 psi pressure gauge in each of the input signal lines to the hydrostatic pump.
3. The gauges may be installed at either of the following:
GC2 on the PCP valve/X1 on the left hand hydrostatic
pump/X2 on the right hand hydrostatic pump.
GC1 on the PCP valve/X2 on the left hand hydrostatic
pump/X1 on the right hand hydrostatic pump
respectively.
NOTE: It is recommended to pick X2 and X1 on the right
hand hydrostatic pump for ease of installation of
the gauges.

5. Start the unit.
6. Set the hydrostatic control lever to a set position in P0002659
either forward or reverse.
7. Record the two readings from the digital multimeters, At the same time, record the pressure readings on
the gauges, noting which pressure pertains to which gauge.
8. One milliamp differential input from the SX Controller to the PCP valve roughly equals 1 psi pressure differ-
ential output from the PCP valve to the hydraulic displacement controls of the pump and motors.
Product Pump Control Valve

The product pump control valve (1) is responsible for
allowing hydraulic oil to the liquid spray pump on the unit
allowing the pump to turn, thereby pushing product out to
the spray booms.
1. 3000 P.S.I. Pressure Gauge.

1
To test the relief valve setting:
1. Install a 3000 psi pressure gauge in the line coming

P0002660
from the gear pump located on the left hand hydro-
static pump and the “P” port on the product pump
control valve.
2. The outlet or “M1” port of the product pump control valve must be blocked off or plugged.
3. Start the engine, then increase engine rpm level to the normal operating range.
4. Record the reading on the gauge.
NOTE: If reading is different than that specified on the hydraulic schematic, adjustment is necessary.

5000 - 11
To test hydraulic flow:
NOTE: A 0-20 or 0-30 gallon per minute flow meter is necessary for this test (preferably one with a load valve).
NOTE: Normal flow rates 17.5 GPM ±.5 GPM.
1. Install the flow meter between the M1 port of the product pump control valve block and the liquid spray
pump, (note the direction of flow indicated on the flow meter). Make sure the load valve is fully open.
2. Check water or liquid level in the product tank and the valves are oriented so as to spray or recirculate.
NOTE: Never operate Product Pump without water or liquid in the product tank.
3. Start the engine and allow the hydraulic oil to warm to 120 degrees F.
4. Turn the liquid pump spray switch on.
5. Increase the engine rpm level to normal operating range or high idle.
6. Record the reading on the flow meter.
NOTE: If the reading is different than specified on the hydraulic schematic, further testing is required.
7. While watching the flow meter, start cranking the load valve down. When the pressure/load increases, if
the flow rate does not decrease, the hydraulic pump is fine. When the pressure/load increases and the flow
rate decreases, the hydraulic pump is becoming weak.
NOTE: If the Flow Meter Test is lower than specifications, further testing of the hydraulic flow from the gear
pump to the product pump control valve must be done.
NOTE: If the Flow Meter Test is within specifications, the

oil is possibly bypassing in the valve block itself
and additional testing of the valve is required.
3 Section Valve Bank

Axle Adjust And Boom Height
If problems are experienced with either of the two above

mentioned functions, some simple testing can be done to
1
rule out the valve block.
1. Check the electrical signal to the solenoid(s) (1) (this

is critical). P0002560
NOTE: When testing the solenoid(s) you should have

+12V at the connector while appropriate function
is used. Coils should measure 10-25 Ohms.
2. If the solenoid is receiving an adequate electrical sig-

nal, the next step is to verify oil flow to the specific 2
function.
3. Either install a flowmeter in one hydraulic line (2) or
disconnect the line and catch the contents in a con-
tainer.
4. Start the engine and warm the hydraulic oil to a mini-
mum of 120 degrees F.
P0002661
5. Activate the desired function. If there is oil flow
through the flowmeter, or oil is collected in the con-

5000 - 12
tainer, the cartridge inside the manifold is working correctly.
Manifold Valve
This component is beneficial for diagnostic purposes.
Several capped ports (G, P4, P5, and P6) are available to
install pressure gauges for testing of the pressure
compensated pump circuits.
1. A 3000 psi pressure gauge may be installed in any of

the above mentioned ports (1). 1
2. Start the engine and warm the hydraulic oil to 120
degrees F.
3. Without activating any boom or axle functions, and
without moving the steering wheel, record the reading P0004155
on the pressure gauge.
NOTE: Compare pressure reading with the specification on the schematic to determine if changes or
adjustments are necessary.
Steering Cylinders
The steering cylinders (1) on this unit are rephasing style.
When the steering wheel is rotated fully clockwise or
1
counterclockwise, it will never come to a positive lock.
1. To test for leaking seals in the steering cylinders,

install cylinder stops as required to keep the stroke of
the cylinder at approximately 1/2 of its full stroke.
2. Start the engine and warm the hydraulic oil to a
minimum of 120 degrees F.
3. Center the front tires. ROD END BLIND END
4. Install cylinder stops to keep the front wheels from
turning when the steering wheel is moved. P0002663
5. Disconnect the hydraulic hose on the opposite end of
cylinder being tested. Example: If your testing the blind end of the cylinder, then disconnect the hydraulic
hose at the rod end).
6. Place the disconnected hose in a collection container.
7. Turn the wheel in the required direction and monitor the amount of oil, that is collected. If no oil is collected,
the seal is intact.
Park Brake Valve Block

• The parking brake is actuated by a cable attached to
the lever on the lower left side of the operator’s seat.
This cable connects to a manifold (1) located near the
left rear outside corner of the cab. As the Park Brake
is engaged or disengaged, the cartridge is actuated to 1
either supply oil to the parking brakes in the hubs or to
prohibit the oil from reaching the hub.
• The parking brakes within the drive hubs are spring
applied and hydraulically released. With the hydraulic
valve properly oriented (brake off), charge pressure
oil is supplied to the brake assembly which
overcomes the spring tension and the brakes are
P0002664
released.
5000 - 13
• Charge pressure oil enters the manifold at port “P” and leaves the manifold towards the drive hubs
at port “A”.
1. If the parking brakes fail to release, disconnecting the hydraulic line at either port “A” on the manifold or at
the point of attachment to the drive hub will be necessary. Have a helper hold the hose into a collection
container.
2. Start the engine and disengage the Park Brake lever. If oil flow is present, the valve is operating properly.
Inner Boom Fold Cylinders

1. Start engine and warm the hydraulic oil to a minimum
of 120 degrees F.
2. Fully extend or retract the cylinder (1) in question.
3. Disconnect the hydraulic line from the end of the
cylinder with the least amount of available volume.
NOTE: Disconnect the rod end if the cylinder is fully 1

extended, or disconnect blind end if the cylinder is fully
retracted.

5. Activate the function so as to attempt to extend a fully P0002665
extended or retract a fully retracted cylinder. If no oil is
expelled, the seal is intact.
Boom Tilt Cylinders

of 120 degrees F.
2. Fully extend or retract the cylinder in question.
3. Disconnect the hydraulic line from the end of the cyl-
inder with the least amount of available volume.
NOTE: Disconnect the rod end if the cylinder is fully

retracted.

P0003180
Activate the function so as to attempt to extend a fully
extended or retract a fully retracted cylinder. If no oil is expelled, the seal is intact.

5000 - 14
Outer Boom Fold Cylinders
of 120 degrees F.

retracted.

5. Activate the function so as to attempt to extend a fully P0002668
Active Suspension Cylinders

Active suspension is a unique option, it senses the load on the front wheels of the
unit.
1
• If one wheel appears to have less of a load than the other, the wheel with the
greater load is “picked up” and the wheel with the lesser load is relaxed.
NOTE: This puts more weight on the slipping wheel, giving it more traction.
• If this does not happen, or if the unit tends to wheel hop while attempting to
climb a hill, there is a possibility of leaking seals in the cylinders (1).
P0002669
Boom Height Cylinders
of 120 degrees F.

retracted.

5. Activate the function so as to attempt to extend a fully
P0002670
• The body/barrel of the cylinder also has two counterbalance valves installed which act as a relief valve/
check valve combination. If a center section seems to settle and the seals in the cylinders test satisfactorily,
it is possible for the oil to be leaking past the check valve portion of the counterbalance valve. As a test, it is
possible to switch the two valves on the cylinder as the check valve portion for the opposite direction
should be functional.

5000 - 15
Neutral Shunt Valve
• The purpose of the neutral shunt valve is to keep any unwanted movement from occurring during the initial
start-up of the unit and any time the unit is in neutral.
• The electric solenoid located on the shunt valve is activated by a signal from the neutral safety switch. This
then shifts the cartridge inside the valve, blocking the oils path to the hydraulic reservoir. It is then allowed
to act on the hydraulic displacement controls of the hydrostatic pump. Provided there is a differential pres-
sure signal, this causes the unit to propel.
6 Section Valve Bank

If problems are experienced with functions related to
boom folding or leveling, some simple testing can be done
to rule out the valve block.
1. Check the electrical signal to the solenoid(s) (this is

critical).
NOTE: Test appropriate switches and wires.
Testing
2. All boom section valves should have +12V from A to B

with the key on.
P0002553
3. With the appropriate section switch on you should
have +12V from C to B.
NOTE: Boom section valves and connectors are located towards the top of the center section.
4. If the solenoid is receiving an adequate electrical signal, the next step is to verify oil flow to the specific
function.
5. Install a flowmeter in one hydraulic line or disconnect
the line, then place the disconnected hose in a collec-
tion container.
6. Start the engine and warm the hydraulic oil to a mini-
mum of 120 degrees F.
7. Activate the desired function. If there is oil flow
through the flowmeter, or oil is collected in the con-
tainer, the cartridge inside the manifold is working cor-
rectly.
8. There are relief valves ported to the blind end pas-
sage inside the valve body.
Test equipment needed for the following test: P0003179

1 - 3000 P.S.I. Gauge
To test this relief valve setting:
1. Place the spray booms in the unit supplied cradles.
2. Install a 3000 psi gauge in the hydraulic line between the valve body and the blind end side of the boom
level cylinder.
3. Start the engine and activate the correct side (right or left depending on where the gauge is installed) to
attempt to push the boom further into the cradle.
4. Record the reading on the pressure gauge.
NOTE: If the reading does not match the specification on the hydraulic schematic, adjustments are necessary.
• There are also two relief valves on the valve body to allow for boom breakaway.

5000 - 16
2 - 3000 P.S.I. Gauges
To test these relief valve settings:
1. Install a 3000 psi gauge in the hydraulic line between the valve body and the blind end side of each/either
inner boom fold cylinder.
2. Install a 3000 psi gauge in the hydraulic line between the valve body and the rod end side of each/either
inner boom fold cylinder.
3. Activate the function so as to take the boom fold to it's full extent of travel or up to some stop.
4. Record the reading on the corresponding pressure gauge.
5. If the reading does not match the specification on the hydraulic schematic, adjustment is necessary.
Hydrostatic Pump Neutral Adjustment

(Not pictured)
4 - 600 P.S.I. Gauges
1. Install one 600 psi gauge in the M4 port on the hydro-

static pump and one 600 psi gauge in the M5 port on
the same hydrostatic pump.
2. Disconnect the hydraulic line running from M5 of the
left hand hydrostatic pump to M4 of the right hand
hydrostatic pump. This will separate the two pumps
from each other.
P0003162
3. Install one 600 psi gauge in the X1 port on the hydro-
static pump and one 600 psi gauge in the X2 port on the same hydrostatic pump.
5. Record the readings on the gauges installed in ports X1 and X2. These readings should be equal.
NOTE: If the above readings are not equal, further testing will need to be done. (Refer to PCP valve testing.)
6. Record the readings on the gauges installed in ports M4 and M5. These readings should be equal with the
hydrostatic control lever in the neutral position.
NOTE: If the above readings are not equal, adjustment must be made to the hydraulic displacement control set
screw. (Reference the Sauer Danfoss literature for the proper procedure.)
7. This process should be repeated for the opposite side hydrostatic pump.

5000 - 17
Hydraulic Oil Cooler
• The purpose of an oil cooler (1) is to take heat out of a
system.
NOTE: Testing of the cooler is relatively simple.
1. Use of a heat gun will determine the difference

between the inlet and outlet temperatures on the
cooler itself. 1
2. If there is not a difference between the temperatures,
the cooler is not functioning properly.
3. Next, install a pressure gauge between the outlet of
the cooler and the hydraulic reservoir. P0003181

5000 - 18
HYDRAULIC SCHEMATIC SYMBOLS

Quick Reference Guide

5000 - 19
HYDRAULIC SCHEMATIC SYMBOLS (Cont’d)

5000 - 20
HYDRAULIC SCHEMATICS AND DIAGNOSTICS

Open Loop
Closed Loop

5000 - 21
Pressure Drop Illustration

5000 - 22
Hydraulic Component Schematics
SPX 4260
SOX Controller PCP Valve
51 Series Wheel Motors

Hydrostat Lever
90 Series Pumps

5000 - 23
90 Series Pump SPX 4260
51 Series Wheel Motors SPX 4260

5000 - 24
90 Series to the 51 Series SPX 4260

5000 - 25
PCP / Servo to Components SPX 4260

5000 - 26
Auxiliary Components SPX 4260

5000 - 27
Product Pump Control Valve SPX 4260
Boom Fold Circuit SPX 4260

5000 - 28
Return to the Tank SPX 4260

5000 - 29
Pump Cavitation
FAULT CAUSE REMEDY
Pump Cavitation Suction strainer clogged or to Clean or renew.

small.
Bore of suction line to small. Fit larger bore pipes.
Too many bends in suction line. Modify pipe layout.
Suction line to long. Reduce length or fit larger bore
pipes.
Fluid to cold. Heat fluid to recommended tem-
perature.
Unsuitable fluid Replace with correct fluid.
Air breather blocked or to small. Clean or replace element.
Local restriction in suction line e.g. Open or modify valves, renew
partly closed valve or hose hoses, etc.
collapse.
Failure of boost pump. Repair or replace boost pump.
Pump running too fast. Reduce to recommended speed.
Pump mounted too high above oil Modify pump installation.
level.
Aeration of Fluid
FAULT CAUSE REMEDY
Aeration of Fluid Reservoir fluid level low. Fill to correct level.

Return line in reservoir above fluid Extend return pipe below fluid level.
level.
Unsuitable fluid. Replace with correct fluid.
Pump shaft seal worn or damaged. Renew seals.
Sit-in line joints allowing entry of Renew or tighten joints.
air.
Porous suction hose. Re-bleed system.
Improper bleeding. Re-bleed system.

5000 - 30
SX CALIBRATION PROCEDURE
Propel Handle Tension Adjustment
Propel handle friction may be increased by tightening
center-lock nut (Item 1) on propel handle shaft.
Increase tension on this nut (Item 1) as necessary to

increase propel handle friction.
Neutral Safety Switch Adjustment

Neutral safety switch is located below propel handle cam.
The neutral safety switch allows the vehicle to start ONLY

in neutral.
The neutral safety switch also activates the shunt valve to

allow the vehicle to propel when NOT in neutral.
1
The position of the switch should be adjusted so that the
neutral position should be centered in neutral cam recess,
while the propel handle is in the neutral position.
NOTE: The point that the switch transfers out of neutral should be equal between forward and reverse.
Reverse Switch Adjustment

The reverse switch is located rearward of the propel
handle cam.
The reverse switch engages the pressure limiter valve to

allow full propel pressure in reverse. This switch also 1
engages the back-up alarm.
The reverse switch should be timed so that it transfers

from NOT in reverse to reverse at approximately the same
time that the neutral safety switch transfers from the
neutral position to NOT in neutral while moving the handle
to the reverse propel position.

5000 - 31
SX CALIBRATION PROCEDURE (Cont’d)

Rotary Position Sensor Calibration Procedure
NOTE: This procedure requires the use of a 3 way Packard breakout adapter and a digital voltmeter having
basic accuracy of.5% or resolution down to.1 mV DC.
1. Install rotary position sensor part number 322638 on

the propel handle shaft (as shown in assembly draw-
ing 321523) with the sensor adjustment screw loos-
ened just enough to move the sensor.
2. Install the 3 way Packard break out adapter between
the rotary position sensor and harness. Attach lead 1
connected to the C terminal to BLACK lead of the volt-
meter, then attach lead connected to the B terminal to
RED lead of the voltmeter.
NOTE: This connection should show the voltage output of

the rotary position sensor while connected to the SX
propel control system.
Break Out Lead Description Pin Typical Voltage

Red Power A-C 5.0 VDC
Green Signal B-C .5 - 4.6 VDC*
Ground Ground C-C 0 VDC
* Depending on handle position.
3. Turn the ignition switch to the ON position (Engine off). Make sure that the park brake is DISENGAGED.
Power to SX control system is cut off while unit is in park. Adjust the sensor such that the voltage mea-
sured with the FNR lever in the neutral position is 2.25 VDC ±.05 VDC. Cycle the propel handle and bring
it to the neutral position from the forward propel position. Reconfirm neutral voltage
(re-adjust if necessary).
NOTE: After calibration, the following voltages may be observed.
Typical Full Forward Voltage (FV) Typical Neutral Voltage (NV) Typical reverse Voltage (RV)
4.40 - 4.6 2.20 - 2.30 .05 -.7
Controller Calibration Procedure

NOTE: This procedure requires an 1/8 inch (3.175 MM.)
drill bit and calibration template P/N 342192A1.
1. Ensure that SX control is not calibrated. Error codes

should be displayed on LEDs located on controller.
Long - long - short - short - long - short - short should
1
be repeated by RED LED.
NOTE: If Error codes are NOT displayed, DO NOT

attempt to calibrate. See Clearing Calibration
2. Disconnect power to SX control. Key off.

3. Place max speed pot to max position. Line up template to indicator knob. Turn knob (Item 1) to cal setting.

5000 - 32
SX CALIBRATION PROCEDURE (Cont’d)

Controller Calibration Procedure (Cont’d)
4. Place the FNR lever in Full ahead position with the 1/8 inch
(3.175 MM.) drill bit (Item 1) between the handle and full ahead
stop.
5. Power up the SX control, with the key ON and engine not run-
ning. Leave the lever and max speed set in position for 5 sec-
onds.
6. Place the FNR lever in the neutral position for 5 seconds.
7. Place the FNR lever to full reverse position for 5 seconds.
8. Rotate max speed set potentiometer to the minimum position for
5 seconds.
9. Cycle the power off, then back on.
10. The calibration should be complete. Check fault LEDs for errors.
If no errors are present, the vehicle is ready to operate. 1
Clearing Calibration Settings

1. Remove power to the SX control (Key off).
2. Unplug the FNR position sensor wire (3 pin Packard) and max
speed sensor (3 pin triangular).
3. Turn on the SX control power.
4. Check that error codes are being displayed.
SX Error Code / Indicator Lights
Power LED Should be green if the system has power applied to it.
System LED Should be green if 5 volt supply is OK.
Light out may indicate a short in the wiring to one of the rotary position sensors.
Mode LED Should flash amber if software is loaded and running.
Status LED Indicates system errors should be off if properly calibrated and operating normally.
Flash codes are as follows:
Long - Long - Short - Short - Indicates a problem with FNR position sensor.
Short - Long - Short - Short - Indicates a problem with Max speed sensor.
NOTE: If flash codes are present, calibration procedure should be performed.
NOTE: If the unit will not calibrate, voltage output of the FNR and Max speed sensors should be per-
formed. Typical voltage ranges, See “Rotary Position Sensor Calibration Procedure” on page 31. Typi-
cal voltage ranges for the Max speed sensor to ground are as follows:
Typical Minimum Voltage (Counterclockwise Position) 0.50 VDC
Typical Maximum Calibrated Voltage 4.40 VDC
Typical Maximum Voltage Clockwise Position) 4.50 VDC

6000
Section 6000
SPRAY SYSTEM

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Spay System
6000 - 3
TABLE OF CONTENTS
SPRAY SYSTEM DIAGNOSTICS

Pump Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Pump Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Check Valve (Rinse) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Sparge Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Boom Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Boom Shut-Off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Pump / Center Section Pressure Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Chemical Inductor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Spray Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Foam Marker Valve / Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Air Tank Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Foamer Liquid Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Foamer Air Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Sparge Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Foam Drop Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
NOTE: Case, LLC reserves the right to make improvements in design or changes in specifications at any time without incurring any
obligation to install them on units previously sold.

Issued 2-03 Printed in U.S.A. Spray System
6000 - 4
SPRAY SYSTEM DIAGNOSTICS
 another
WARNING: Be sure to clean and flush all residual chemicals from the sprayer before changing to
type of chemical. In some cases a decontamination solution is recommended by the
chemical manufacturer.
The operator should always wear protective clothing and equipment when working around liquid
fertilizer and/or chemicals.
Agricultural chemicals can be dangerous. Improper selection can seriously injure persons, animals,
plants soil, or property. Be safe: Select the right chemical for the job. Handle it with care. Follow the
instructions on the container label and appropriate instructions contained in this Operators Manual.
See the tote bag for more information.
Pump Seal
If the product pump (Item 1) is “ran dry” it will damage the
liquid seal.
If a chemical leak is found, replace the liquid seal.
NOTE: If the seal is not replaced, it will eventually

damage the hydraulic motor seals.
Inspect the hydraulic motor seals. If a hydraulic leak is

found, replace the hydraulic motor seals.
1
P0002890
Pump Vent
If the vent hose (Item 1) is plugged or kinked, it will cause
an air lock to develop in the pump.
Inspect the vent, unplug or unkink the vent. 1
P0002891

6000 - 5
Check Valve (Rinse)
The check valve (Item 1) is located between the fresh
water rinse tank and the product pump.
NOTE: This check valve prevents contamination from

entering the fresh water rinse tank.
If the fresh water rinse tank has been contaminated,

inspect the check valve for debris.
1
Remove any debris found or replace if necessary.
P0002892
Sparge Valve
The sparge valve (Item 1) is located between the liquid
pump and the sparge tube.
NOTE: The sparge valve is used to regulate the amount

of liquid circulated into the product tank for agitation.
Check the following if the sparge valve is not fuctioning

properly.
1. Switch - Repair or replace. 1

2. Wire Connections - Repair or replace.
3. Valve function - Repair or replace. P0002893
Flow Control Valve

If the controller will not maintain flow rates.
Check to see if the flow control valve (Item 1) is

functioning properly.
P0002894

6000 - 6
Strainer
Lose of flow or pressure.
Inspect the strainers (Item 1) for debris. They must be in 1

good working condition.
Clean or replace strainers as necessary.
NOTE: It is important that the strainers are clean and in

good working condition. The strainers protect the spray
tips from damage and clogging.
P0002899
Boom Pressure Sensor

Check the following if the boom pressure sensor (Item 1)
is not fuctioning properly.
1. Switch - Repair or replace.

2. Wire Connections - Repair or replace.
3. Sensor function - Repair or replace.
NOTE: The transducer (1) provides the input to the boom 1

pressure monitor mounted on the right hand A-post.
P0002900
Boom Shut-Off Valve

If the boom valves are not operating properly or
responding too slowly.
1. Check the power supply to the boom shut-off valve. 1

2. Inspect the boom shut-off valve.
3. If chemical is leaking from the weep hole (Item 1),
replace the boom shut-off valve with a new correct
part number valve.
P0002901

6000 - 7
Pump / Center Section Pressure Switches
The pump pressure switch (Item 1) monitors the output 1
pressure of the product pump.
The center section switch (Item 2) monitors the spray

pressure at the center section.
2
If the pressure drops below 14 p.s.i. on either of the
switches, the switch closes and lights the pump or center
section pressure indicator located on the indicator light
cluster.
P0004158
Chemical Inductor
With the inductor rinse valve on, the rinse tube (Item 2)
will spray. Press down on the rinse valve (Item 1) to
activate the jug rinse valve.
P0002904
Spray Nozzle
If the nozzle body (Item 1) drips chemical.
1. Inspect the diaphragm and o-ring.

2. Replace any worn or damaged components.
1
The best way to determine if a spray tip is excessively
worn is to compare the flow rate from the used tip to the
flow rate of a new tip of the same size and type.
2
NOTE: Spray tips are considered excessively worn when
their flow rate exceeds the flow of a new tip by 10% and
should be replaced. P0002905
3. Test the flow rate of each tip by using an accurate graduated collection container, a timing device and an
accurate pressure gauge mounted at the nozzle tip (Item 2).
4. Compare the flow rate of the old tip to that of the new one.

6000 - 8
Foam Marker Valve / Strainer
If the foam marker is not operating properly or insufficient
amount of liquid. 1
2
1. Close the ball valve (Item 1), located at the foam tank
discharge.
2. Remove the strainer housing and strainer (Item 2).
3. Inspect the strainer for debris.
4. Clean the strainer if necessary or replace the strainer
if it is damaged.
P0002908
Air Tank Drain

A petcock (Item 1) is supplied on the air reservoir.
This petcock allows any water that may have entered into 1
the tank to be drained. Also air pressure can be released
prior to working on the pneumatic system.
P0002911
Foamer Liquid Solenoid

The foamer liquid solenoid (Item 1) is located on the
center section.
The foamer liquid solenoid directs the flow of liquid to the 1

right or left boom. This solenoid is controlled by a push
button switch located on the hydrostatic control lever.
If there is no liquid flow to right or left boom.
1. No liquid in foam reservoir. Fill reservoir.

2. Check the wire connection at the solenoid and at the
switch. Repair or replace as necessary.
P0002913
3. Switch not operating correctly. Replace switch.

6000 - 9
Foamer Air Solenoid
There is one foamer air solenoid (Item 1) located on each
boom near the mixing chamber.
The foamer air solenoid controls the air entering the

mixing chamber. This solenoid is controlled by a push
button switch located on the hydrostatic control lever.
Solenoid not operating properly.
1. No air pressure at solenoid. Check air supply lines. 1

2. Check the wire connection at the solenoid and at the
switch. Repair or replace as necessary.
P0002914
3. Switch not operating correctly. Replace switch.
Sparge Transducer
The transducer (Item 1) provides the input to the sparge
monitor mounted on the right hand A - post. Verify
pressure reading on gauge against true sparge pressure.
The sparge pressure reading at monitor and true sparge

pressure should be the same. If these readings are not
the same replace the transducer.
1
P0002916
Foam Drop Assembly

If the foam marker system is working, but delivering poor
quality foam.
1. Inspect the foam drop assembly (Item 1).

2. Disassemble and clean the foam drop assembly if
necessary. Replace the assembly if it is damaged.
P0002915

7000
Section 7000
A/C SYSTEM

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. A/C System
7000 - 3
TABLE OF CONTENTS
SAFETY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
A/C COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
ATC Cab Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Serviceable Components - Automatic Temperature (ATC) . . . . . . . . . . . . . . . . . . . . . . .9
Serviceable Components - Standard A/C System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPX 4260 Chassis Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
ACCESSING THE A/C UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

A/C Electrical Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Automatic Temperature Control (ATC) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Operational Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mode Door Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ATC Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Standard A/C Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Smart Pressure Switch Cycling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A/C Thermal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
STANDARD A/C TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Standard A/C Electrical Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
High Pressure Switch and Circuit Test (Standard A/C) . . . . . . . . . . . . . . . . . . . . . . . . . 20
Low Pressure Switch and Circuit Test (Standard A/C) . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Blower Speed Switch and Circuit Test (Standard A/C) . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Blower Motor Test (Standard A/C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
A/C ON/OFF Switch and Circuit Test (Standard A/C). . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Temperature Control Potentiometer and Circuit Test (Standard A/C). . . . . . . . . . . . . . . 26
Heater Control Valve Power Supply and Ground Test (Standard A/C) . . . . . . . . . . . . . . 27
Clutch Relay Power Supply and Ground Test (Standard A/C) . . . . . . . . . . . . . . . . . . . . 27
A/C Compressor Control Circuit Test (Standard A/C). . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Standard A/C Controller Power Supply and Ground Test. . . . . . . . . . . . . . . . . . . . . . . . 28
Evaporator Temperature Sensor and Circuit Test (Standard A/C) . . . . . . . . . . . . . . . . . 29
Mode Door Control Potentiometer and Circuit Test (Standard A/C) . . . . . . . . . . . . . . . . 30
Mode Door Motor and Circuit Test (Standard A/C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cab Pressurizer Blower Relay Supply & Ground Test (Standard A/C). . . . . . . . . . . . . . 33
EXTERNAL COMPRESSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Compressor and Fan Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Pulley and Belt Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
OPERATIONAL MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Keyed Power - Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Defog/Defrost Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7000 - 4
BLOWER AND TEMPERATURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Blower Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Blower Speed - Temperature Control - ATC Switch - LCD Display . . . . . . . . . . . . . . . . 37
Controller Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ATC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
MODE DOOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Mode Door Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Mode Door Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ATC CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ATC Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Low And High Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CAB TEMPERATURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Air Louvers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Air Conditioner Hose Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Louver Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
HOSES AND HEATER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Compressor Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Heater Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Heater Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
EVAPORATOR AND PLENUM CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Plenum Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CAB AND EVAPORATOR TEMPERATURE SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Cab and Evaporator Sensor Resistance versus Temperature . . . . . . . . . . . . . . . . . . . 48
CAB PRESSURIZER BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

7000 - 5
SAFETY PROCEDURES
 WARNING: 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.
ATTENTION: Only authorized technicians certified by an approved training and certification organization may
service or repair motor vehicle or mobile air conditioning systems.
Refrigerant HFC-134a is the most stable and easiest to work with of the refrigerants now used in air
conditioning systems. Refrigerant R-134a does not contain chlorofluorocarbons (CFC’s) which are harmful to
the earth’s ozone layer.
Safety procedures must be followed when working with refrigerant HFC-134a to prevent possible personal
injury.
1. Always wear combination impact and chemical splash safety goggles when doing any service work near
an air conditioner system. Liquid refrigerant in the eyes can cause serious injury. Do the following if you get
refrigerant near or in your eyes:
2. Flush your eyes with water for 15 minutes.
3. See a physician immediately.
4. Always reclaim all refrigerant prior to opening an A/C system. (See Air Conditioning System Service Sec-
tion.) A drop of liquid refrigerant on your skin may cause frostbite burns. Open fittings carefully and slowly
when servicing the air conditioning system. Your skin must be treated for frostbite or a physician must be
seen if you get refrigerant on your skin.
5. Keep refrigerant containers in correct upright position. Always keep refrigerant containers away from heat
and sunlight. The pressure in a container will increase with heat.
6. Always check refrigerant purity with the OEM-4450 Refrigerant Identifier before recovering refrigerant and
before testing the system. See Air Conditioning System Service Section.
7. Use the air-powered OEM-1691 ONLY to recover contaminated refrigerant. Do NOT use OEM-1415 or
Oem-1418 recycling stations to recover contaminated refrigerant. If contaminated refrigerant contains
more than 2% hydrocarbon (propane, butane or isobutance), the mixture must be considered flammable; if
more than 4% hydrocarbon, the mixture must be treated as explosive; in both cases an electric-powered
recovery station may NOT be used. Avoid heat, sparks and flame when working with this contaminated
refrigerant.
8. Dangerous gas can form when refrigerant comes in contact with an open flame. Never inhale fumes.
9. Never leak test with compressed air or flame tester. Tests have indicated that compressed mixtures of
HFC-134a and air can form a combustible gas.

7000 - 6
SPECIAL TOOLS
Belt Tension Tool CAS-10808
299L7C
OEM-1415 Refrigerant Recovery Station
6 Foot Length, Quick Disconnect Refrigerant Charging

Hoses: OEM-1438 (Yellow), OEM-1439 (Blue),
OEM-1440 (Red)
20 Foot Length, Quick Disconnect Refrigerant Hoses -

OEM 1442 (Set includes Yellow, Blue and Red hoses)
A22094
Compressor Tool Set, CAS-10747A
The compressor dipstick can be found in the

Compressor Tool Set or purchased separately -
CAS-10747-19.
RD99K079
9 Inch Stem Type Thermometer 0° TO 250°F CAS-

10248
29917B
Combination Impact and Chemical Splash Safety Goggles
299L7A

7000 - 7
Refrigerant Identifier OEM-4450
RR99M070

7000 - 8
A/C COMPONENTS
ATC Cab Component Locations
3
5
6
7
RP99E009
1. Blower Speed Driver.

2. ATC Controller.
8
3. Thermal Expansion valve.
4. Heater Control Valve.
5. Blower Motor.
6. Evaporator Core.
7. Evaporator Temperature Sensor.
8. Cab Temperature Sensor. 9
9. Compressor Clutch Relay.
RP99E009

7000 - 9
Serviceable Components - Automatic Temperature (ATC)
16
2
15
13 2B
2A
12 17 8
7
9 3
11
14 18
19 10
RI00A099
1. LID ASSEMBLY 6. HEATER VALVE ASSEMBLY 13. BASE WELDMENT

2. ATC/BLOWER SPEED DRIVER 7. HEATER/EVAPORATOR COIL 14. EVAPORATOR BOX ASSEMBLY
MOUNTING PLATE ASSEMBLY ASSY
A. ATC CONTROLLER 8. A/C SUCTION LINE 15. CAB TEMPERATURE SENSOR
B. BLOWER SPEED DRIVER 9. A/C LIQUID LINE 16. COMPRESSOR CLUTCH RELAY
3. BLOWER ASSEMBLY 10. HEATER SUPPLY LINE 17. THERMAL EXPANSION VALVE
4. WIRE HARNESS (NOT SHOWN) 11. HEATER RETURN LINE 18. DRAIN HOSE
5. A/C LOW PRESSURE SWITCH 12. EVAPORATOR TEMPERATURE 19. CHECK VALVE
SENSOR

7000 - 10
Serviceable Components - Standard A/C System
17
14
7 6 4A
13 9
10
8
4B
2
16
18
15
19 11 12 3
RI99M043
1. LID ASSEMBLY 6. LOW PRESSURE SWITCH 13. EVAPORATOR TEMPERATURE
SENSOR
2. STANDARD A/C CONTROLLER 7. HEATER/EVAPORATOR 14. BASE WELDMENT
ASSEMBLY
3. BLOWER ASSEMBLY 8. HEATER VALVE ASSEMBLY 15. EVAPORATOR BOX ASSEMBLY
4. RESISTOR ASSEMBLY 9. A/C SUCTION LINE TUBE 16. THERMAL EXPANSION VALVE
A. RESISTOR 10. A/C LIQUID LINE TUBE 17. CLUTCH RELAY
B. MOUNTING BRACKET 11. HEATER SUPPLY TUBE 18. DRAIN HOSE
5. WIRE HARNESS (NOT SHOWN) 12. HEATER RETURN TUBE 19. CHECK VALVE

SPX 4260 Chassis Components
320605
MODEL 4260
HIGH PRESSURE SWITCH (NOT SHOWN) 6. COMPRESSOR TO CAB HOSE
3. CONDENSOR MOUNT 7. DRYER TO CAB HOSE
4. A/C HOSE 11. CONDENSOR COIL
5. COMPRESSOR TO CONDENSOR HOSE 12. RECEIVER DRYER
7000 - 11
A/C System
7000 - 12
ACCESSING THE A/C UNIT

NOTE: The following procedure applies to both the standard
A/C and Automatic Temperature Control (ATC) systems.
1. Disconnect the harness to the right hand control console. 1

2. For tractors equipped with mechanical remote hydraulic
controls, the right hand control console must be discon-
nected from the seat:
A. Loosen the 13 mm nut (Item 1) at the front of the right
side of the seat.
B. Remove the 18 mm bolt (Item 2) at the right hand rear 2
of the seat. Disconnect the harness connector to the
console and remove the console.
RD99N151
3. Tilt the steering wheel to the full upright position. Adjust
seat to the full upright and back position.
4. Remove four bolts (Item 1) in seat base corners.
RD99N152
5. Disconnect the seat harness (Item 1).

6. Hinge seat forward and rest on steering wheel.
1
7. After completion of service, reconnect seat harness. Realign
ATC controller mounting plate, if equipped, with mounting
holes and reinstall seat mounting hardware. Reinstall right
hand control console (if applicable). Reconnect right hand
control harness. Check that cab recirculation air filter is prop-
erly installed.
RD99N153

7000 - 13
THEORY OF OPERATION
A/C Electrical Operation
Automatic Temperature Control (ATC) Systems
INPUTS OUTPUTS
CAB TEMPERATURE SENSOR A/C COMPRESSOR ENGAGEMENT VIA RELAY
EVAPORATOR TEMPERATURE SENSOR HEATER CONTROL VALVE POSITION
SETPOINT TEMPERATURE BLOWER SPEED CONTROL VIA PWM SIGNAL
LOW PRESSURE SWITCH STATUS DATA FOR LIQUID CRYSTAL DISPLAY
HIGH PRESSURE SWITCH STATUS CONDITIONED POWER FOR SERVO ACTUATOR
(+12V)
OFF/AUTO/DEFOG SWITCH LCD CONDITIONED POWER (+5V)
MANUAL BLOWER SPEED CONTROL MODE DOOR MOTOR
°F/°C DISPLAY SELECTION
MANUAL MODE DOOR CONTROL
B+
COMMON GROUND
GROUND
The ATC is a closed loop control device which takes the data from a variety of inputs and executes output
instructions to the devices it controls. The desired controlling parameter is cab inside temperature. The
operator selects a desired cab temperature set point. The controller then utilizes the A/C compressor,
electronic heater control valve, mode doors and system blower to drive the cab temperature to and hold the
desired set point. This is done through a variety of controlling algorithms and look-up tables which define the
controller’s response based upon the current actual cab temperature and the desired cab temperature set
point.
Manual adjustment of the blower speed overrides the ATC controller’s control of this function. Blower speed will
remain at the operator selected setting and the “A” on the LED display will disappear until the system is shutoff
and turned back on to AUTO. Temperature control will continue to be automatic regardless of blower speed, but
set point may not be attained if blower speed setting is too low.
Manual adjustment of the mode door also overrides the ATC controller’s control of this function. Mode door
position will remain at the operator selected setting and the “A” on the LED display will disappear until the
system is shut back off and turned back on to AUTO. Temperature control and blower speed will continue to be
automatic regardless of mode door position, but set point may not be attained as readily.
Operational Modes
In AUTO mode, the A/C compressor only runs or heater control valve opens when needed to achieve or
maintain cab temperature set point.
In DEFOG/DEFROST mode, the compressor runs continuously to remove moisture from the air until the
evaporator temperature sensor reaches its freeze setting. In DEFOG/DEFROST mode, the heater control valve
is opened only when required to achieve or maintain the desired set point.
In OFF mode, the A/C compressor and heater control valve are turned off, but the blower motor continues to
circulate air at the rate selected by the operator.
In AUTO and DEFOG/DEFROST modes, blower speed selected by the controller is based on the difference
between actual cab temperature and the set point. The greater the difference, the greater the speed. However,
on cold days at start-up, to avoid blowing cold air on the operator, blower speed will default to 25% and will not
be increased until the temperature sensed by the evaporator temperature sensor exceeds 55°F (12.8°C). This
feature also applies when the maximum heat setting is selected.
Mode Door Function

In AUTO mode, as the controller uses the A/C compressor or heater control valve with varying blower speed
to achieve the cab temperature set point, the controller also directs the flow of air to the floor, mid-cab or
defog/defrost vents using the mode door motor and mode control potentiometer. Where the air flow is directed
depends on the cab temperature set point selected or the position of the ATC switch:

7000 - 14
If the cab temperature set point is greater than 73° F (22.8°C), air is directed to the floor vents. If cab
temperature set point is less than 72° F (22.2°C), air is directed to the mid-cab vents.
If an operator raises cab temperature set point by more than 10° F (5.6°C) warmer, air flow is directed to the
floor vents. If an operator lowers cab temperature set point by more than 10° F (5.6°C) cooler, air flow is
directed to the mid-cab vents.
If the DEFOG/DEFROST position on the ATC switch is selected, all air flow is directed to the defog/defrost
vents at the windshield. Air flow will continue to exit the defog/defrost vents until the ATC switch is set to the
OFF or the AUTO position.
ATC Temperature Range

The range for the Automatic Temperature Control is from 16 to 30°C (61 to 89°F). A maximum A/C and heat
mode is provided at display set points of 16 and 32°C (60 to 90°F). While in this maximum mode, the controller
will provide the HVAC system’s maximum capacity and disregard the cab inside air temperature.
For maximum A/C the evaporator temperature sensor controls compressor clutch cycling. The blower is
automatically increased to the maximum speed. In both conditions, the “A” icon on the display will be turned off
while at these settings.
In DEFOG/DEFROST mode, when the temperature control is turned to the maximum heat position and the
heater control valve is fully open, the compressor is still controlled by the evaporator temperature sensor.
Standard A/C Systems

The standard A/C controller is an open loop control device. The controller provides electronic thermostat
control. The compressor clutch is engaged and disengaged by the standard controller. The clutch is cycled
from 18 to 37°C (32 to 66°F) evaporator temperature sensor values proportional to the temperature control
potentiometer position from 12 o’clock to full counterclockwise.
The standard controller opens the heater control valve from full closed to full open position proportional to the
temperature control potentiometer position from 12 o’clock to full clockwise. If cab temperature is desired to be
made cooler or warmer or if the air path is to be diverted, it is the operator who makes the adjustment. (See
diagram below.)
Maximum Cold Maximum Hot

RD99D022
Standard A/C Temperature Control
Smart Pressure Switch Cycling System

Both the ATC and standard systems are equipped with pressure switch cycle counters. The compressor will
not be locked out until four cycles of the low pressure switch occur or until two cycles of the high pressure
switch occur within a 60 second rolling interval which starts with the first cycle of the switch.
The ATC display will display a 02 ATC fault code for the low pressure switch and 01 ATC fault code for the high
pressure switch.
A/C systems must operate for over 1 minute before any high or low pressure fault codes are displayed. All other
fault codes are displayed immediately after the fault occurs. The fault codes are not stored.

7000 - 15
For additional fault code description, see ATC Fault Codes in this Section.
The standard A/C controller will blink the indicator light (mounted in the A/C on/off switch) slowly, approximately
7 times in a 10 second period for the low pressure switch, or quickly, approximately 13 times in a 10 second
period for the high pressure switch.
NOTE: On cool days below 40°F, the A/C system may not operate due to the low pressure switch lock out even
though the cab temperature is warm. The system is not malfunctioning if this occurs. To provide the necessary
A/C compressor protection, Case A/C systems are not designed to operate on days below 40°F.
A/C Thermal Operation
The refrigerant circuit of the air conditioning system contains five major components: compressor, condenser,
receiver-drier, expansion valve and evaporator. These components are connected by tubes and hoses and
operate as a closed system. The air conditioner system is charged with HFC-134a refrigerant.
See diagram on next page to follow refrigerant flow.
The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the
refrigerant and sends it in the form of a high pressure gas to the condenser. The air flow through the condenser
then removes the heat from the refrigerant. As the heat is removed the refrigerant changes to a high pressure
liquid.
The high pressure refrigerant liquid then flows from the condenser to the receiver-drier. The receiver-drier is a
container filled with moisture removing material, which removes any moisture that may have entered the air
conditioner system in order to prevent corrosion of the internal components of the air conditioner system.
The refrigerant still in high pressure liquid form, then flows from the receiver drier to the expansion valve. The
expansion valve provides a restriction to refrigerant flow to cause a pressure drop which allows the liquid
refrigerant to expand, decreasing its temperature and pressure. This low temperature low pressure liquid then
flows through the evaporator core. The hot cab air passes through the evaporator fins cooling the air and
evaporating the liquid refrigerant. The low pressure gas returns to the compressor and the cycle starts all over
again.
The electrical circuit of the ATC air conditioning system consists of:
• 5 amp fuse (fuse no. 27) for HVAC Controller,

• 30 amp fuse (fuse no. 26) for the HVAC blower,
• 15 amp fuse (fuse no. 32) for the cab pressure blower,
• 5 amp fuse (fuse no. 24) to change LCD from °F to °C,
• ATC switch (Auto/Off/Defog),
• blower speed control potentiometer,
• temperature control potentiometer,
• mode door control potentiometer,
• LCD display,
• evaporator temperature sensor,
• cab temperature sensor,
• heater control valve,
• cab pressurizer blower motor,
• HVAC blower motor,
• mode door motor,
• A/C compressor clutch,
• compressor clutch relay,
• A/C high pressure switch,
• A/C low pressure switch,
• ATC Controller,
• and a blower speed driver for the blower motor.

7000 - 16
LOW PRESSURE GAS

LOW PRESSURE LIQUID
HIGH PRESSURE GAS
HIGH PRESSURE LIQUID
209L95
1. COMPRESSOR 3. RECEIVER-DRIER 5. EVAPORATOR
2. CONDENSOR 4. THERMAL EXPANSION VALVE

7000 - 17
STANDARD A/C TROUBLESHOOTING

NOTE: The batteries must be fully charged and all connections clean and tight. Use a multimeter (DVOM) for
these tests.
CAUTION: DO NOT use a self-powered test light for any of these tests. Use of a self-powered test light can
cause damage to components in this system.
WARNING: Before performing any of the electrical tests, be sure all operating controls are in neutral or park
lock position.
Standard A/C Electrical Troubleshooting

Symptom Possible Cause Test or Reference
Standard A/C system is Power and ground to Standard A/ See “Standard A/C Controller
inoperative C controller Power Supply and Ground Test”
on page 28.
Fuse 27
See “A/C Compressor Control
Circuit Test (Standard A/C)” on
page 28.
A/C ON/OFF switch defective See “A/C ON/OFF Switch and
Circuit Test (Standard A/C)” on
page 25.
Compressor operates, but blower Power and ground to blower See “Blower Motor Test (Standard
is inoperative. motor A/C)” on page 23.
Fuse 26

7000 - 18
Blower operates, compressor is High pressure switch activated See “Low And High Pressure
inoperative. locking out the clutch Switches” on page 42.
Standard A/C controller blinks See “High Pressure Switch and
indicator light (in the A/C ON/OFF Circuit Test (Standard A/C)” on
switch) quickly, approximately page 20.
thirteen times in a 10 second
period
Low pressure switch activated See “Low And High Pressure
locking out the clutch Switches” on page 42.
Standard A/C controller blinks See “Low Pressure Switch and
indicator light (in the A/C ON/OFF Circuit Test (Standard A/C)” on
switch) slowly, approximately page 21.
seven times in a 10 second period
Evaporator temperature sensor See “CAB AND EVAPORATOR
disconnected or defective, locking TEMPERATURE SENSORS” on
out the clutch page 48.
See “Evaporator Temperature
Sensor and Circuit Test (Standard
A/C)” on page 29.
Loose or broken drive belts See “Compressor and Fan Belts”
on page 34.
Power and ground to clutch relay See “Clutch Relay Power Supply
and Ground Test (Standard A/C)”
Clutch relay defective
on page 27.
Compressor clutch defective Replace clutch. See Air
Conditioning System Service
Section.
Compressor defective. Replace compressor. See Air
Conditioning System Service
Section.
Blower operates, no heat, too Heater control valve defective See “Heater Control Valve” on
much heat or heat output cannot (Control valve can fail in any page 46.
be changed. position - open, closed, midway.)
See “Heater Control Valve Power
Power and ground to heater Supply and Ground Test
control valve (Standard A/C)” on page 27.
Temperature control See “Temperature Control
potentiometer disconnected or Potentiometer and Circuit Test
defective (Standard A/C)” on page 26.
Coolant not hot See cooling system section of
service manual
Blower inoperative Blower speed switch See “Blower Speed Switch and
disconnected or defective Circuit Test (Standard A/C)” on
page 22.
Blower motor defective See “Blower Motor Test (Standard
A/C)” on page 23.

7000 - 19
Blower operates but not at all Blower speed switch See “Blower Speed Switch and
speeds: no low speed and/or no disconnected or defective Circuit Test (Standard A/C)” on
medium speed but high speed page 22.
operates.
Blower motor defective See “Blower Motor Test (Standard
A/C)” on page 23.
Motor resistor disconnected or See “Blower Motor Test (Standard
defective A/C)” on page 23.
Mode doors cannot be moved Power and ground to mode door See “MODE DOOR CONTROL”
from current position with the control potentiometer on page 39.
control.
Mode door control potentiometer See “Mode Door Control
disconnected Potentiometer and Circuit Test
(Standard A/C)” on page 30.
Mode door control potentiometer See “Mode Door Control
defective Potentiometer and Circuit Test
In-line resistor has failed to mode See “Mode Door Motor and
door motor. Circuit Test (Standard A/C)” on
page 32.
Power and ground to mode door See “Mode Door Motor and
motor. Circuit Test (Standard A/C)” on
page 32.
Motor defective.
Cab pressurization blower does Cab pressurizer relay See “Cab Pressurizer Blower
not run when engine RPM disconnected or defective. Relay Supply & Ground Test
exceeds 500. (Standard A/C)” on page 33.
Power and ground to cab See “Cab Pressurizer Blower
pressurizer blower relay. Relay Supply & Ground Test
W i r i n g p r o bl e m f r o m e n g i n e Engine controller detects that the
g ove r n o r t o c a b p r e s s u r i ze r governor cannot locate the
blower relay. pressurizer relay and displays a
fault code. See engine manual.

7000 - 20
High Pressure Switch and Circuit Test (Standard A/C)
Steps and Test Point Corrective Actions

NOTE: The high pressure switch is a normally closed switch. The switch will open if the refrigerant pressure
on the high side exceeds 400 psi ± 10 psi (2758 kPa ± 69 kPa). The switch will then reset once the
refrigerant high side pressure drops below 250 psi ± 10 psi (1724 kPa ± 69 kPa).
1. Verify flashing light on A/C ON/OFF switch.
NOTE: The A/C system must operate for at least one minute before flashing the light.
2. Refer to A/C Troubleshooting Foldout and follow Y E S - Pe r fo r m c o r r e c t i ve a c t i o n s f r o m A / C
the conditions for performing a pressure test. Troubleshooting Foldout.
Install A/C high and low side pressure gauges. NO - Go to next Step.
High reading above 400 psig ± 10 psig (2758
kPa ± 69 kPa)?
3. Shut off the machine. Inspect high pressure OK - Go to next Step.
switch and connections for damage, bent or NOT OK - Connect switch correctly and retry unit.
dislocated pins or improper seating.
NOT OK - Go to next Step.
4. Disconnect the switch from the harness and the OK - Reinstall switch and go to next Step.
unit. Check that switch is closed across pins 1 NOT OK - Replace switch.
and 2.
5. Confirm continuity from pin 1 on pressure switch OK - Replace standard A/C controller.
through connectors 60, 333 and 139 to terminal NOT OK - Locate open circuit and correct.
C on the six pin connector on standard A/C
controller. Confirm ground through SPL-F3 and
SPL-F2 to ring terminal 148 on pin 2.

7000 - 21
Low Pressure Switch and Circuit Test (Standard A/C)

NOTE: When disconnected from the harness and the unit and properly functioning the low pressure switch
is normally open.
NOTE: The switch will test as closed when refrigerant pressure is present greater than 4 psi (28 kPa). The
switch will trip open if the refrigerant pressure on the low side drops below 4 psi ± 2 psi (28 kPa ± 14
kPa). The switch will then reset once the refrigerant low side pressure rises above 20 psi ± 3 psi (138
kPa ± 21 kPa).
1. Verify flashing light on A/C ON/OFF switch.
NOTE: The A/C system must operate for at least one minute before flashing the light.
2. Refer to the A/C Troubleshooting Foldout and Y E S - Pe r fo r m c o r r e c t i ve a c t i o n s f r o m A / C
follow the conditions for performing a pressure Troubleshooting Foldout.
test. Install A/C high and low side pressure NO - Wiring problem to the switch or defective
gauges. Low reading below 4 psi ± 2 psi (28 kPa switch. Go to next Step.
± 14 kPa)?
3. Refer to Accessing the A/C Unit in this Section.
4. Shut off the tractor. Inspect low pressure switch OK - Go to next Step.
and connections for damage, bent or dislocated NOT OK - Connect switch correctly and retry unit.
pins or improper seating.
5. Disconnect the switch from the harness and the YES - Go to next Step.
unit. Does the switch test open across pins A NO - Replace the switch.
and B?
6. Confirm continuity from pin B on pressure switch OK - Replace the standard A/C controller.
to ter minal B on the five-pin connector on NOT OK - Locate open circuit and correct.
standard A/C controller and pin A on pressure
switch to HVAC ground.

7000 - 22
Blower Speed Switch and Circuit Test (Standard A/C)

1. Put ignition switch in RUN position.
2. Measure voltage at blower speed switch YES - Go to Step 4.
connector 126 on terminal B. Is 12V present? NO - Fuse no. 26 is bad or there is an open circuit in
blower speed switch power supply circuit. Go to next
Step.
3. Measure voltage at fuse 26 on fuse block 261. Is YES - Locate and repair open circuit in 495(R).
12 volt present? NO - Replace fuse.
NOT OK - Locate and repair open circuit in switched
B+ power to fuse. Go to next Step.
4. Turn blower control to LOW speed position. YES - Go to next Step.
Me asure vo lta ge at blower spee d switch NO - Replace switch.
connector 126 on terminal E. Is 12V present?
5. Turn blower control to MEDIUM speed position. YES - Go to next Step.
connector 126 on terminal D. Is 12V present?
6. Turn blower control to HIGH speed position. YES - Switch is operating properly.
connector 126 on terminal C. Is 12V present?

7000 - 23
Blower Motor Test (Standard A/C)

1. Put ignition switch in the RUN position.
2. Turn blower control to HIGH speed position. YES - Go to Step 5.
Does blower motor operate at high speed? NO - Problem with blower motor or blower motor
control circuits. Go to next Step.
3. Disconnect the motor. Is there continuity through YES - Go to next Step.
the motor? NO - Replace motor.
4. Measure voltage at blower motor on wire from YES - Go to next Step.
terminal H on the resistor. Is 12V present? NO - Problem with blower motor control circuits. Go
to next Step.
5. Turn blower control to LOW speed position. YES - Go to Step 10.
Does blower motor operate at low speed? NO - Problem with blower motor control circuit. Go to
next Step.
6. Measure voltage at blower motor resistor YES - Locate and repair open circuit between blower
terminal L. Is 12V present? motor resistor and blower motor. If no open circuit
found, replace resistor.
NO - There is an open circuit in switched B+ circuit
to blower motor resistor. Go to next Step.
7. Measure voltage at terminal 2 of blower motor YES - Locate and repair open circuit between in-line
resistor in-line connector. Is 12V present? connector terminal 2 and blower motor resistor
terminal L.
NO - There is an open circuit in switched B+ to
blower motor resistor. Go to next Step.
8. Measure voltage at in-line connector 139M on YES - Repair open circuit between connector 139 on
pin D. Is 12V present? pin D and in-line connector on terminal 2.
9. Measure voltage at blower speed switch YES - Locate and repair open circuit in 498(Or).
connector 126 on terminal E. Is 12V present? NO - There is a problem with blower switch or
Switched B+ circuit. See “Blower Speed Switch and
Circuit Test (Standard A/C)” on page 22.
10. Turn blower control to MEDIUM speed? Does YES - Go to Step 15.
blower motor operate at medium speed? NO - Go to next Step.
11. Measure voltage at blower motor resistor on YES - Replace blower motor resistor.
terminal M. Is 12V present? NO - There is an open circuit in switched B+ to
12. Measure voltage at terminal 3 of blower motor YES - Locate and repair open circuit between in-line
resistor in-line connector. Is 12V present? connector terminal 3 and blower motor resistor
terminal M.

7000 - 24
Blower Motor Test (Standard A/C) (Continued)
13. Measure voltage at in-line connector 139M on YES - Locate and repair open circuit between
pin E. Is 12V present? connector 139M on pin E and in-line connector
terminal 3.
14. Measure voltage at blower switch connector 126 YES - Locate and repair open circuit in 497(Or).
on terminal D. Is 12V present? NO - See “Blower Speed Switch and Circuit Test
15. Turn blower control to HIGH speed position. YES - Blower motor and blower motor resistor are
Does blower motor operate at high speed? operating properly.
NO - Problem with blower motor control circuits. Go
to next Step.
16. Measure voltage at blower motor resistor in-line YES - Locate and repair open circuit between in-line
connector on terminal 4. Is 12V present? connector and blower motor resistor on terminal H.
NO - There is a problem with blower motor control
circuits. Go to next Step.
17. Measure voltage at in-line connector 139M on YES - Locate and repair open circuit between
pin G. Is 12V present? connector 139 on pin G and blower motor resistor in-
line connector terminal 4.
NO - There is a problem with blower motor control
circuits. Go to next Step.
18. Measure voltage at blower speed switch YES - Locate and repair open circuit in 496(Or).
connector 126 on terminal C. Is 12V present? NO - See “Blower Speed Switch and Circuit Test

7000 - 25
A/C ON/OFF Switch and Circuit Test (Standard A/C)

1. Shut off tractor.
2. Open overhead control panel and inspect A/C OK - Go to next Step.
switch and connections for damage, bent or NOT OK - Connect switch correctly and retry unit.
dislocated pins or improper seating.
3. Disconnect switch from connector 128. Put A/C YES - Go to next Step.
switch in ON position. Is there continuity across NO - Replace switch.
pins D and E?
4. Check for continuity across terminals A and C of OK - Go to next Step.
switch?. NOT OK - Replace A/C switch.
5. Reconnect switch. Put switch in ON position. OK - Go to next Step.
Confirm continuity from pin E on A/C switch NOT OK - Locate open circuit and correct.
through connector 139 to pin E on the six-pin
connector on standard A/C controller.
6. Confirm continuity from pin D on A/C switch, OK - Go to next Step.
502(N) to chassis ground at ring terminal 172B. NOT OK - Locate open circuit and correct.
7. Put ignition switch in RUN position. Measure YES - Go to Step 10.
voltage at A/C switch connector 128 on terminal NO - Fuse no. 18 is bad or there is an open circuit in
C. Is 12V present? switched B+. Go to next Step.
8. Measure voltage at strobe/beacon switch YES - Locate and repair open circuit in 503(R).
connector 129 on terminal E. Is 12V present? NO - Fuse no. 18 is bad or there is an open circuit in
489(R) or 152(R) from switched B+.
9. Measure voltage at fuse 18. Is 12V present? YES - Locate and repair open circuit in11(R).
NO - Replace fuse.
NOT OK - Locate and correct open circuit in 11(R).
10. Put ignition switch in OFF position. Disconnect YES - Go to Step 12.
switch from connector 128. Disconnect five-pin NO - Locate and repair open circuit in 499(Or). Go to
c o n n e c t o r f r o m s t a n d a r d A / C c o n t r o l l e r. next Step.
Measure resistance from terminal A on A/C
switch to terminal C on the five-pin connector.
Less than 1 ohm?
11. Measure resistance from in-line connector 139M YES - Locate and repair open circuit in 499(Or).
to terminal C on five-pin connector at standard NO - Locate and repair open circuit in pressure
A/C controller. Less than 1 ohm? warning circuit between terminal C on five-pin
connector at standard A/C controller and connector
139.
12. Reconnect all electrical connectors. Put ignition OK - A/C switch and circuits are okay.
switch in RUN position and A/C switch ON. NOT OK - See “Low Pressure Switch and Circuit
Disconnect electrical connector from A/C low Test (Standard A/C)” on page 21.
pressure switch. Does light flash on the A/C
switch?

7000 - 26
Temperature Control Potentiometer and Circuit Test (Standard A/C)

1. Shut off tractor.
2. Open the overhead panel and inspect OK - Go to next Step.
temperature potentiometer and connector for NOT OK - Connect potentiometer correctly and retry
damage, bent or dislocated pins or improper unit.
seating.
3. Put ignition and A/C switch in the OFF position. OK - There is a problem with power and ground
Disconnect the potentiometer from the harness. between standard A/C controller and potentiometer.
Check for variation in resistance (0 - 10K ± 10% Go to next Step.
ohms) across B and C on connector 125F while NOT OK - Replace potentiometer.
turning the control.
NOTE: Turn the control slowly and check for any

dead spots - points of infinite resistance -
across the range of the potentiometer.
4. Check for 10K ± 10% ohms across pins A and C OK - Power and ground between controller and
on connector 125F. potentiometer or controller fault. Go to next Step.
NOT OK - Replace the potentiometer.
5. Install jumper wires between 125M and 125F YES - Temperature control potentiometer tests okay.
connectors on pins B and C. Turn keyswitch and Replace the standard A/C controller.
A/C switch ON. Is 5V present at pins B and C? NO - There is a problem with power or ground. Go to
next Step.
6. Confirm continuity from B on temperature OK - Go to next Step.
control through connector 139 on pin T to NOT OK - Locate open circuit and correct.
terminal D on six-pin connector at the standard
A/C controller.
7. Measure resistance from C on the control NO - Locate open circuit and correct.
through connector 139 on pin S to HVAC
ground. Less than 1 ohm?

7000 - 27
Heater Control Valve Power Supply and Ground Test (Standard A/C)

2. Measure resistance from terminal 7 on heater YES - Go to next Step. There is a problem with
control valve to HVAC ground? Less than 1 power supply or control signal.
ohm? NO - Locate open circuit and correct.
3. Disconnect connector from terminal 10 on OK - Go to next Step.
heater control valve to terminal E on the five-pin NOT OK - There is an open circuit in the power
connector at the standard A/C controller. Check supply to the valve. Locate and correct. Go to the
continuity in the wire. next Step.
4. Disconnect connector from terminal 8 on the OK - Go to next Step.
heater control valve to terminal D on the five-pin NOT OK - There is an open circuit in the control
connector at the standard A/C controller. Check circuit to the heater control valve. Locate and
continuity in the wire. correct.
5. Reconnect all connections. Toggle ignition from YES - Heater control valve and circuits okay.
OFF to RUN. Measure voltage at heater control NO - Replace standard A/C controller.
valve terminal 10. Voltage present with ignition
in RUN position and no voltage in OFF?
Clutch Relay Power Supply and Ground Test (Standard A/C)

2. Put ignition switch in the RUN position and A/C OK - Check compressor clutch.
switch in ON position. Put blower speed switch NOT OK - Go to nest Step.
in any position but OFF. Confirm that the relay is
properly functioning by cycling the switch on and
off. A properly functioning relay can be heard
engaging.
3. Measure the voltage on terminal 3 of the relay. Is YES - Go to Step 6.
12V present? NO - There is an open circuit from terminal F on
blower speed switch to clutch relay. Go to next Step.
4. Check for continuity between terminal 3 on OK - Go to next Step.
clutch relay through connector 139 to terminal F NOT OK - Locate and repair open circuit.
on blower speed switch.
5. Check continuity between terminal 1 on clutch OK - Go to next Step.
relay and terminal A on the five-pin connector at NOT OK - Locate open and repair open.
standard A/C controller.
6. Check for continuity between terminal 5 on relay OK - Replace relay.
and compressor clutch harness. NOT OK - Locate open circuit and repair between
terminal 5 on relay and terminal C on connector 139,
to pin 26 on connector 333, to pin P on connector
60, through pin 1 on connector 72 and onto the
compressor clutch.

7000 - 28
A/C Compressor Control Circuit Test (Standard A/C)

NOTE: This procedure assumes that test gauges have already been installed and that a low or high
pressure problem in the A/C system has been eliminated as the cause for the compressor not working.
1. Put ignition switch in RUN position. Set blower YES - A/C compressor circuits are okay.
speed switch in any position but OFF. Cycle A/C NO - There is an open circuit in switched B+ or
switch ON and OFF. Can you hear compressor compressor clutch or clutch relay is defective. Go to
clutch engaging and disengaging? next Step.
2. Put ignition switch in RUN position and A/C YES - Replace compressor clutch.
switch in ON position. Put blower speed switch NO - See “Clutch Relay Power Supply and Ground
in any position but OFF. Measure voltage at Test (Standard A/C)” on page 27. Perform Steps 2-5.
compressor clutch connector 72M. Is 12V
present? NOT OK - Go to next Step.
3. Disconnect A/C high pressure switch connector YES - See “High Pressure Switch and Circuit Test
71. Install jumper across terminals 1 and 2. (Standard A/C)” on page 20. Perform Steps.
Does compressor clutch engage? (Remove NO - There is a problem with low pressure switch or
jumper and reinstall switch when completed.) control circuit.
4. Put ignition switch in RUN position and A/C YES - Replace low pressure switch.
switch in ON position. Put blower speed switch NO - See “Low Pressure Switch and Circuit Test
i n a ny p o s i ti on bu t O F F. D i s c on n e c t l ow (Standard A/C)” on page 21. Perform Steps.
pressure switch connector. Install jumper
between terminals A and B. (Remove jumper
and reinstall switch when completed.) Does
compressor clutch engage?
Standard A/C Controller Power Supply and Ground Test

2. Put ignition switch in the RUN position. Measure YES - Go to Step 5.
the vo ltage on te r m inal A on the six-pin NO - Fuse no. 25 is bad or there is an open circuit in
connector at standard A/C controller. Is 12V B+ supply to controller. Go to next Step.
present?
3. Measure voltage at in-line connector 139M YES - Repair open circuit between connector 139F
terminal R. Is 12V present? terminal R and standard A/C controller terminal A.
NO - Go to next Step.
4. Check fuse no. 25 (5 amp). Is 12V present? YES - Repair open circuit in 123(K) between fuse
no. 25 and connector 139.
NOT OK - There is an open circuit from fuse no. 25
to switched B+. Locate and correct. Go to next Step.
5. Measure resistance from terminal F on six-pin YES - Standard A/C controller supply and ground
connector at standard A/C controller to HVAC are okay.
ground. Less than 1 ohm? NO - Repair open circuit from standard A/C
controller l terminal F to HVAC ground.

7000 - 29
Evaporator Temperature Sensor and Circuit Test (Standard A/C)

1. Shut off sprayer.
3. Inspect evaporator temperature sensor and OK - Go to next Step.
connector for damage, bent or dislocated pins or NOT OK - Connect sensor correctly and retry unit.
improper seating.
4. Disconnect the evaporator temperature sensor OK - Reinstall the sensor and go to next Step.
from harness. Check the resistance across both NOT OK - Replace sensor.
leads for a value of 20-25K ohms at normal
room temperature.
5. This sensor can be failing without generating a YES - Replace the sensor.
fault code. Measure the resistance of the sensor NO - Go to next Step.
and your ambient temperature, and compare the
readings to the Temperature versus Resistance
char t on page 48 in this Section. Do your
readings vary from the chart by more than 3%?
6. Confirm continuity from female connector on OK - Replace standard A/C controller.
evaporator temperature sensor to terminal B on NOT OK - Locate open circuit and correct.
six-pin connector at standard A/C controller and
from ring ter minal on the sensor to HVAC
ground.
NOTE: Verify that the sensor is installed in the correct location. The temperature sensor must be installed
4.2 inches (107 mm) from the left hand rear side of the evaporator. The sensor must be installed below
the second refrigeration row at a 30° downward angle. Insert the sensor in the evaporator core up to the
angled section.

7000 - 30
Mode Door Control Potentiometer and Circuit Test (Standard A/C)

1. Shut off sprayer.
2. Open the overhead panel and inspect mode OK - Go to next Step.
door potentiometer and connector for damage, NOT OK - Connect potentiometer correctly and retry
bent or dislocated pins or improper seating. unit.
3. Put ignition in the RUN position and A/C switch YES - Resistor has failed. Go to next Step 9.
ON. Check the operation of the potentiometer NO - Go to next Step.
while turning the control. Resistance should
change on the potentiometer across pins A and
C and the door actuator should move according
to the table below:
NOTE: Remove a louver on the left hand front side

of the mid-cab vents to observe operation of the
mode door.
Pot
Actuator
Ohms Angle
100% Mid-cab Vents ....................... 0K -45°
100% Floor Vent.............................. 5K 0°
100% Defog Vents ......................... 10K +45°
If the mode door motor continues to run after the
door has reached its +45° position, the resistor
has failed. Does the motor continue to run after
the door is fully moved?
4. Put ignition and A/C switch in the OFF position. OK - There is a problem with power and ground to
Disconnect the switch from the harness. Check potentiometer, signal to motor, with the resistor or a
for variation in resistance (0 - 10K ± 10% ohms) controller fault. Go to next Step.
across B and C on connector 279M while NOT OK - Replace potentiometer.
turning the control.
NOTE: Turn the control slowly and check for any

dead spots - points of infinite resistance - across the
range of the potentiometer.
5. Check for 10K ± 10% ohms across A and C on OK - There is a problem with power or ground, with
connector 279M. the resistor or with the controller. Go to next Step.
NOT OK - Replace the potentiometer.
6. Install jumper wires between 279F and 279M YES - Mode door potentiometer tests okay. There is
connectors on pins A and C. Turn key switch and a problem with the control circuit to the motor. Go to
A/C switch ON. Is 5V present between pins A See “Mode Door Motor and Circuit Test (Standard A/
and C? C)” on page 32.
NO - There is problem with power or ground to the
potentiometer. Go to next Step.

7000 - 31
Mode Door Control Potentiometer and Circuit Test (Standard A/C) (Continued)
7. Confirm continuity from A on mode door control OK - There is a problem with ground to
potentiometer through connector 139 on pin Y to potentiometer, signal to motor, with the resistor or a
terminal E on five -pin connector at the standard controller fault. Go to next Step.
A/C controller. NOT OK - Locate open circuit and correct.
8. Measure resistance from C on the control YES - There is a problem with signal to motor, the
through connector 139 on pin S to HVAC resistor or a controller fault.
ground. Less than 1 ohm? NO - Locate open circuit and correct.
9. Confirm continuity through the resistor between YES - Resistor tests okay. Replace the controller.
SPL-CD4 and SPL-CD5 on 190(Or). Is the NO - Replace the resistor.
resistance 39Kohms?
NOTE: The resistor is located on the right hand side

of the steering console.

7000 - 32
Mode Door Motor and Circuit Test (Standard A/C)

1. The mode door motor is located in the front
steering console on the front left hand side. See
ACCESSING THE MODE DOOR MOTOR in the
Air Conditioning System Service Section.
NOTE: Remove the ignition switch from the console

cover and reconnect the switch to the harnesses
when performing this test.
2. Inspect the mode door motor and connector for OK - Go to next Step.
damage, bent or dislocated pins or improper NOT OK - Connect motor correctly and retry unit.
seating.
3. Disconnect the motor from the harness and OK - Go to next Step.
check for continuity through the motor on pins NOT OK - Replace the motor.
10 and 7.
4. Install jumper wires across pins 7, 8 and 10 YES - Go to Step 6.
between the harness connector and the motor. NO - There is an open circuit between pin 10 on the
Put ignition switch in RUN position and A/C motor (through connectors 7 and 139) and terminal
switch ON. Measure voltage at pin 10 on E on the five-pin connector at the standard A/C
connector 70. Is 12V present? controller or a controller fault. Go to next Step.
5. Measure voltage at terminal E on five-pin YES - There is an open circuit between terminal E
connector at the standard A/C controller. Is 12V on 5-pin connector on the standard A/C controller
present? (through connectors 139 and 7) and pin 10 on the
motor. Locate and correct. Go to next Step.
NO - Replace the standard A/C controller.
6. Measure resistance at pin 7 on connector 70 at YES - There is a problem with the control signal from
the mode door motor through SPL-CD1 through the mode door potentiometer on pin B to pin 8 on
pin 29 on connector 7 through SPL-C24 to ring motor or a potentiometer fault. Go to next Step.
terminal 173D. Less than 1 ohm? NO - Locate open and correct.
7. Disconnect the resistor on 190A (Or) to pin 8 on YES - Reconnect resistor and go to next Step.
connector 70. Is there continuity through the NO - Replace resistor. Retry the unit.
resistor.
NOT OK - There is a problem in the control circuit or
with the motor. Go to next Step.
8. Check for varying voltage at pin 8 on connector YES - Control circuit is OK.
70 while turning the mode door control. Is 12V NO - There is a problem with the control signal to the
present? motor or potentiometer fault. Go to next Step.
9. Check for varying voltage at pin B on the mode YES - Locate open circuit between pin B on control
door control potentiometer while turning the potentiometer through pin 15 on connector 7 and pin
control. Is 12V present? 8 at the mode door motor on 190A(Or) and correct.
NO - Go to next Step.
10. Put ignition and A/C switch in the OFF position. OK - See , page 29. Perform Steps 4 and 5.
Disconnect the potentiometer from the harness. NOT OK - Replace potentiometer.
Check for variation in resistance (0 - 10K ± 10%
ohms) across A and C of mode door
potentiometer while turning the control.

7000 - 33
Cab Pressurizer Blower Relay Supply & Ground Test (Standard A/C)

NOTE: The cab pressurizer blower relay is located
in the electronics compartment on the right hand
side of the operator’s seat.
NOTE: The cab pressurizer blower is located under

the instructional seat behind a trim panel at the cab
rear.
1. Start the tractor and run the engine at RPM

greater than 500 to engage the cab pressurizer
blower.
2. The engine controller should recognize any fault
conditions from the control side (pin 2) of the
cab pressurizer blower relay. Check for engine
controller fault codes and follow instructions
provided. See engine manual.
3. Check fuse #32 on block 262. Is 12V present? YES - There is a problem with power and ground to
the relay or the blower motor is defective. Go to next
Step.
NO - Replace fuse 32 (15 amp) and/or locate and
correct open circuit to the fuse.
4. Measure the voltage on pin A on connector 90 at YES - There is an open circuit between the motor
the cab pressur izer blower motor. Is 12V and the relay or the motor is defective. Go to next
present? Step.
NO - Locate and correct open circuit on 92(R).
5. Disconnect the cab pressurizer motor from the OK - There is an open circuit between the motor and
harness and check for continuity through the the cab pressurizer blower relay. Go to next Step.
motor between pins A and B. NOT OK - Replace the cab pressurizer blower
motor.
6. Measure the resistance on terminal 5 on the cab YES - There is a problem with the ground circuit to
pressurizer blower relay. Less than 1 ohm? the relay. Go to next Step.
NO - Locate and correct the open circuit between
the motor and terminal 5 of the relay on 130(Bk).
7. Measure resistance on terminal 3 on the cab YES - Replace the cab pressurizer blower relay.
pressurizer relay to ring terminal ground 173. NO - Locate the open circuit and correct.
Less than 1 ohm?

7000 - 34
EXTERNAL COMPRESSOR CHECK

Compressor and Fan Belts
1. Check for loose or broken drive belt. The compressor drive
belt is self-tensioning on the SPX 4260.
NOTE: Check tension with Belt Tension Tool (Item 1).
2. Adjust the tension on a new belt to 95 to 115 lbs (422 to

516 N) and to 90 to 110 lbs (400 to 489 N) after a minimum
of 10 minutes run-in time on the belt. Belt tension on a
used belt must be 90 to 110 lbs (400 to 489 N).
3. Check for too much belt wear - replace a worn belt, 1
because a worn belt will cause excessive slippage.
RD00B013
Compressor Mounting Bracket

1. Check for loose mounting bolts on the bracket (Item 1) and
adjusting strap. Tighten the bolts to the correct torque.
If bracket or adjusting strap have breaks or cracks, replace
them.
DCP01773-2
Compressor Clutch
1. The compressor belt will slip on the compressor
clutch pulley if there is compressor seizure. Remove
the compressor for replacement. See Air Conditioning
System Service Section in this service manual.
2. Remove the three Torx® screws (Item 1) and remove

the dust cover (Item 2). Check air gap clearance
between the clutch plate and the pulley. A spark plug
1
gauge with 90° wire feelers may be used to check ini-
tial air gap in the field.
RD99N142

7000 - 35
3. Slip the wires between the clutch plate and the pulley and
check the gap at the three rivets. The gap must be 0.016 to
0.031 inch (0.41 to 0.79 mm). The gap must be even all the
way around the plate. See Air Conditioning System Service
Section for adjusting the air gap in clutch replacement.
RD99N145
4. Use a socket wrench to slowly rotate the compressor clock-
wise. Compressor rotation should be smooth and not
require much effort. If severe rough spots or catches are
felt when turning the shaft, the compressor has been dam-
aged internally and must be replaced.
Pulley and Belt Alignment RD99N144
The compressor pulley (Item 1) and the compressor drive

pulley (Item 2) must be aligned within 1/16 inch (1.6 mm) of
each other. Use a straight edge to check pulley alignment.
Adjust the compressor mounting bracket if needed. The drive
belt should be located in the forward clutch groove.
RD00B015

7000 - 36
OPERATIONAL MODES
1
Keyed Power - Automatic Mode
1. With the ignition switch in the ON position and the ATC
switch (1) in AUTO, the system will operate the blower
motor and the A/C compressor clutch or heater control
valve if the cab temperature is greater or less
respectively than 2°F (1.1°C) from the current
temperature set point. If the cab temperature is 2°F
(1.1°C) warmer than set point, the compressor will be
engaged and the blower speed will be incremented. If
the cab temperature is 2°F (1.1°C) colder than set point, RD99N127
the heater control valve will be opened and the blower
speed will be incremented.
NOTE: In AUTO mode, the greater the difference between actual cab temperature and the set point, the
greater the blower speed. As actual temperature approaches the set point, blower speed decreases and the
ATC controller varies blower speed to maintain the set point. If an operator adjusts the blower speed
manually, the ATC unit no longer operates in automatic mode; the “A” disappears from the display.
Blower speed will remain constant at the speed selected by the operator. If the selected blower speed is too
low, the ATC unit may not be able to achieve the desired set point or will achieve it very slowly. To return to
AUTO mode, the ATC switch must be toggled to OFF and then back to AUTO. The “A” will display and the ATC
controller will adjust blower speed automatically again to achieve the desired set point.
NOTE: At start up on cold days when the set point is calling for heat, blower speed will default to low speed
and will not be incremented until heater core temperature sensed exceeds 55°F (12.8°C) to avoid blowing cold
air on the operator. This feature applies to Automatic and Defog/Defrost modes. Moving the temperature
control to the maximum heat position will not override this feature.
2. If the compressor and blower both do not work, check fuse no. 27.
3. If only the blower motor does not work, check fuse no. 26.
Defog/Defrost Mode 1
Defog/defrost mode operates similarly to Automatic mode

except that the compressor runs continuously to remove
moisture from the air in the cab until the evaporator
temperature sensor senses -2°F (-19°C) and cycles the
compressor on or off, depending on the temperature value at
the sensor. Temperature control and blower speed are
automatic. This is more important in a heating situation where
the controller is warming the cab to achieve the set point. The
RD99N127
controller will increase blower speed and open the heater
control valve further to maintain the desired heat set point even though the compressor is running continuously.
In a cooling situation, the controller will not turn off the compressor if the set point is achieved. The controller
only disengages the compressor when the evaporator temperature sensor senses -2°F (-19°C).
Here also, if an operator adjusts blower speed manually, while the defog/defrost icon will continue to display on
the LCD, blower speed control will no longer be automatic. Blower speed will default to whatever the operator
has selected, and the controller may not be able to achieve the desired set point or will achieve it very slowly.
Turning the ATC switch (Item 1) to OFF and then back to DEFOG/DEFROST position will return blower speed
to automatic control.
The maximum heat setting on the temperature control will not disengage the compressor in defog/defrost
mode.

7000 - 37
BLOWER AND TEMPERATURE CONTROL

Blower Speed
In Manual mode, where the heater control valve and compressor are turned off, blower speed is incrementally
variable within the range of the potentiometer - 30 positions - for the circulation of air in the cab. In Automatic
and Defog/Defrost modes, the controller uses the blower to achieve the cab temperature set point. Controller
blower speed selection is based on the difference between the actual cab temperature and the desired set
point according to the chart below:
Temperature Difference Blower Speed

≤ 2°F (≤1.1°C) 25%
> 2°F but ≤ 4°F
35%
(> 1.1°C but ≤ 2.2°C)
> 4°F but ≤ 6°F
45%
(> 2.2°C but ≤ 3.3°C)
> 6°F but ≤ 8°F
55%
(> 3.3°C but ≤ 4.4°C)
> 8°F but ≤ 10°F
65%
(> 4.4°C but ≤ 5.5°C)
> 10 °F but ≤ 12°F
75%
(> 5.5°C but ≤ 6.6°C)
> 12°F (> 6.6°C) 100%
Blower Speed - Temperature Control - ATC Switch - LCD Display

To check the blower speed or temperature control potentiometer operation:
1. Check the resistance across A and C for a value of 10K ohms ± 10%. Check for proper operation across B
and C on the potentiometer connector while turning the control. Resistance changing as the control is
turned indicates the potentiometer is functioning. If the potentiometers have failed open or out of range, an
ATC fault code of 04 for blower speed control potentiometer and 05 for temperature control potentiometer
will be displayed.
NOTE: If the blower speed potentiometer fails the blower will default to maximum speed. If the temperature
control potentiometer fails, the cab temperature setting will default to 68°F.
2. The ATC Switch - Auto/Off/Defog - connects a ground sig-

nal to the ATC Controller to indicate the selected mode. 2
3. The LCD display indicates the operator selected set point

in degrees Fahrenheit that can be converted to degrees
Celsius by installing a 5 amp fuse in cavity no. 24 in fuse
block 261. Removing the 5 amp fuse from cavity no. 24
will return the display to degrees Fahrenheit. In addition
the Auto mode is indicated by an “A” and the defog/defrost
icon is illuminated when that mode is selected. 1 3
NOTE: When an ATC fault code is displayed, the display will
cycle between the code and the current set point and will
RD99N127
illuminate the service manual with wrench icon. See ATC Fault
Codes in this Section for additional description and 1. BLOWER CONTROL
troubleshooting. 2. A/C SWITCH (CCM) OR ATC SWITCH.
3. TEMPERATURE CONTROL

7000 - 38
Controller Initialization
During controller initialization on start-up, it is normal for the 4
display to flash 88 and to illuminate all icons when power is
1
first applied. If 88 flashes continuously and will not clear on
the LCD, the controller is not initializing correctly. Check power
and ground to the controller, or the controller may be
defective.
2 3
RH98G032
1. DIGITAL TEMPERATURE SETTING

2. DEFOG/DEFROST MODE INDICATOR
3. AUTOMATIC MODE INDICATOR
4. SERVICE INDICATOR
Blower Motor
1. Check the voltage for the blower motor at the motor leads
directly attached to the motor. With the blower speed
control set at maximum, the reading should be
approximately 12 volts. (Actual voltage will vary
depending on battery strength, what additional
accessories are on, etc.)
NOTE: If the blower speed potentiometer fails, the blower will
default to maximum speed.
ATC Switch RP99E005
1. With the key in the run position, the ATC switch in the
DEFOG/DEFROST position, and the temperature
control set for maximum cooling, listen for an audible 1
click from the engine compartment when the
compressor clutch engages (if the engine is not
running).
2. Test the circuits from the ATC switch (Item 1) to confirm
continuity back to the HVAC unit. If a ground to the 2
appropriate wire pin on the switch connector does not
cause the compressor clutch to engage, check the
clutch relay (located under the operators seat) and com-
pressor clutch in the engine compartment.
RD99N127
3. With the switch on DEFOG/DEFROST (Item 2), confirm
that the relay is functioning by cycling the ATC switch on and off. A properly functioning relay can be heard
engaging. If the relay does not engage, See “Clutch Relay Power Supply and Ground Test (Standard A/C)”
on page 27.

7000 - 39
4
6
7
3
1 2 5
RB99N034
1. BLOWER OFF 3. MAXIMUM COOL - 15.5° C 5. MAXIMUM HEAT - 32° C 7. OFF POSITION
(60 F) (90° F)
2. MAXIMUM BLOWER 4. ATC RANGE 6. AUTO MODE 8. DEFOG/DEFROST MODE
SPEED
MODE DOOR CONTROL

Standard A/C Units: The flow of air to the defog/defrost,
mid-cab or floor vents is operator controlled.
ATC Units: The ATC controller, responding to operator
changes to the cab temperature set point or the position of
the ATC switch, directs the flow of air for the operator. As
the controller uses the A/C compressor or heater control
1
valve with varying blower speed to achieve the cab
temperature set point, the controller also directs the flow of
air to the cab floor, mid-cab or defog/defrost vents using the
mode door motor and mode control potentiometer. In AUTO
RD99N127
mode where the air flow is directed depends on the cab
temperature set point (Item 1) selected:
If the cab temperature set point is greater than 73°F
MID - CAB DEFOG / DEFROST
(22.8°C), air flow is directed to the floor vents. If cab
temperature set point is less than 72°F (22.2°C), air
flow is directed to the mid-cab vents (2).
If an operator raises cab temperature set point by more
than 10° F (5.5°C) warmer, air flow is directed to the
floor vents. If an operator lowers cab temperature set
point by more than 10°F (5.5°C) cooler, air flow is
directed to the mid-cab vents.
P0001347

7000 - 40
If an operator adjusts the mode door position manually, the
ATC unit no longer operates in automatic mode; the “A”
disappears from the display. Mode door position will remain
constant in the position selected by the operator. Temperature
control and blower speed control will remain automatic. To
return to automatic mode door control, the ATC switch must
be returned to the OFF and then AUTO position.
If the DEFOG/DEFROST position on the ATC switch is
selected, all air flow is directed to the defog/defrost vents at
the windshield. Air flow will be to the defog/defrost vents until
the ATC switch is returned to the OFF and then AUTO FLOOR
position.
P0001348
Mode Door Potentiometer

To check the mode door potentiometer operation:
1. ATC: Check the resistance across A and C for a value of 10K ohms ± 10%. Check the resistance across B
and C for a value of 0-10K ohms ± 10%. Check for proper operation across B and C on the potentiometer
connector while turning the control and observe the position of the actuator. Resistance changing as the
control is turned indicates the potentiometer is functioning, and the door actuator should move according to
the table below.
NOTE: Remove a louver from the front console and use a flashlight to observe actuator operation.
Pot Actuator
Mode Door
Ohms Angle
100% Mid-cab Vents 0K -45°
100% Floor Vent 5K 0°
100% Defog Vents 10K +45°
2. If the potentiometer has failed open or out of range, an ATC

fault code of 07 will be displayed. If the motor continues to
run after the door has reached the +45° position, the resis-
tor has failed and must be replaced.
3. Standard A/C: Check the resistance across A and C for a
value of 10K ohms ± 10%. Check for proper operation
across B and C (0-10K ohms ± 10%) on the potentiometer
connector while turning the control and observe the posi-
tion of the actuator. Resistance changing as the control is
turned indicates the potentiometer is functioning.
Mode Door Motor
RD99N166

7000 - 41
See Mode Door Control Potentiometer and Circuit Test
(Standard A/C), page 30. Door Actuator
(This picture RD99N168 shows front console with louvers

and cover removed)
Mode Door Motor
Mode Door Motor RD99N168
1. ATC: The mode door motor is fed power from the controller
pin L on the five pin connector through pin Y on connector
139 to the motor on pin 10. Ground for the motor is
supplied at pin 7 through SPL-CD1 through pin 29 on
connector 7 through SPL-C24 to ring terminal 173D.
Disconnect the motor from the harness and check for
continuity through the motor on pins 7 and 10. If no
continuity, replace the motor.
Standard A/C: The mode door motor is fed power from the
controller pin F on the five pin connector through pin Y on
Mode Door Motor
connector 139 to the motor on pin 10. Ground for the motor
is supplied at pin 7 on the motor through SPL-CD1 through RD99N166
pin 29 on connector 7 through SPL-C24 to ring terminal
173D. Disconnect the motor from the harness and check for continuity through the motor on pins 7 and 10.
If no continuity, replace the motor.
2. Check power and ground to the mode motor.
3. The motor receives its control signal on pin 8. Check for variation in voltage on pin 8 while turning the mode
door control. For ATC units, the controller modulates the voltage. For standard A/C units, the potentiometer
modulates the voltage while an in-line resistor to pin 8 on the motor limits travel of the mode door itself.
Disconnect the resistor and check for continuity through the resistor. See “Mode Door Motor and Circuit
Test (Standard A/C)” on page 32.

7000 - 42
ATC CONTROLLER
ATC Controller
1. Check for high and low pressure shutdown. The compressor clutch will not operate if the system pressure
is too high, above 400 ± 10 psi (27.6 bar), or too low below 4 ± 2 psi (0.07 bar). A 01 ATC fault code will
display on the LCD display for a high pressure condition, a 02 ATC fault code will display for low pressure
condition. Cycling the ignition off and back on or the ATC switch off and back on will reset the system.
NOTE: Fault codes for high and low pressure will not be displayed until the unit has been on for 1 minute.
Standard A/C Systems: the standard controller will blink the indicator light in the A/C ON/OFF switch slowly,
approximately 7 times in a 10 second period, for low pressure switch activation and quickly, approximately 13
times in a10 second period for high pressure switch activation.
NOTE: The LED in the standard A/C ON/OFF switch can fail in the closed position, at which time the diode will
remain constantly lit. Replace the A/C ON/OFF switch.
2. The controller actuates the compressor clutch via a relay located in the back of the HVAC unit. Confirm that
the relay is functioning by cycling the ATC switch on and off. A properly functioning relay can be heard
engaging.
3. Verify that the controller is being fed B+ on terminal D3 and that the grounds are clean and secure. See
“Standard A/C Controller Power Supply and Ground Test” on page 28.
ATC Controller Blower Speed Driver Clutch Relay

(Behind The Evaporator)
RD99N055 RP99E010
Low And High Pressure Switches

1. When disconnected from the system, the low pressure
switch will test normally open; the high pressure switch
will test normally closed.
NOTE: When installed in the A/C system under normal

operating conditions, the low pressure switch will test as
CLOSED.
1
The low pressure switch (Item 1) closes in the presence of
pressure greater than 4 ± 2 psi (28 kPa ± 14 kPa). If the
system pressure drops below 4 ± 2 psi (28 kPa ± 14 kPa)
the switch contact will open, the compressor clutch will be
disengaged, and a counter will be set inside the ATC RD99N046
controller or the standard A/C controller.

7000 - 43
NOTE: Once the system pressure rises above 20 ± 3 psi (138 kPa ± 20 kPa) the switch will reset and the
compressor will be allowed to engage after 20 ± 3 psi (138 kPa ± 20 kPa) is reached or 10 seconds elapse,
whichever is longer. This will occur as long as there are no more than three switch actuations within a 60
second interval. On the fourth occurrence within a 60 second interval, the compressor will be locked out, a 02
ATC fault code will be displayed, and a manual reset is required. The standard controller blinks an indicator
light in the A/C ON/OFF switch approximately seven times in a 10 second period.
The high pressure switch (Item 1) opens when the

high side system pressure exceeds 400 ± 10 psi
(2758 kPa ± 69 kPa). The switch will reset once high
side pressure drops below 250 ± 10 psi (1724 kPa ±
69 kPa).
NOTE: The same counting system applies except a
lockout and 01 ATC fault code will display on the second 1
switch actuation within a 60 second interval. The standard
controller blinks an indicator light in the A/C ON/OFF
switch approximately 13 times in a 10 second period.
2. Using a piercing lead from a digital volt meter, check

for switch continuity between terminal 2 and ground.
Test the circuits for continuity back to the ATC Control- MK99J192
ler. See “High Pressure Switch and Circuit Test (Stan-
dard A/C)” on page 20. See “Low Pressure Switch and Circuit Test (Standard A/C)” on page 21.
With engine OFF, system pressure will equalize on low and high sides to approximately 75 psi (520 kPa) at
room temperature. Both pressure switches should remain closed. To check system pressure, refer to Air
Conditioning System Service Section.
Compressor Clutch
1. The compressor clutch must disengage when the wire
lead to the clutch is disconnected.
2. Measure system voltage. Minimum system voltage is
12V.
3. Measure coil resistance between connector (1) and
bracket ground. 2.8K to 3.3K ohms is the range of coil
resistance. Infinite resistance indicates open circuit.
4. 12V should be present at harness connector with key
in RUN position, recirculation blower running, system 1
pressures not triggering high or low pressure shut-
downs, ATC switch set to DEFOG/DEFROST or stan-
dard A/C switch to ON and evaporator core
temperature above -2°F (-19°C). RD00B023

7000 - 44
5. See “Clutch Relay Power Supply and Ground Test
Clutch Relay (behind the evaporator)
CAB TEMPERATURE CHECK RD99N055
Air Louvers
1. Make sure the cab discharge louvers are open.
2. Make sure the blower control is set on maximum and
the air conditioner temperature control is on maxi-
mum.
Air Conditioner Hose Check MK99J201
3. With the engine running and ATC switch set to

DEFOG/DEFROST mode or A/C switch to ON,
carefully feel the air conditioner hoses. The high
pressure hose (Item 1) must be much warmer than
the low pressure hose (Item 2).
MK99J191
WARNING: The high pressure hose may be very hot. When checking it’s temperature, touch
! it very briefly to avoid burning yourself.
4. If there is no temperature difference between the hoses, the compressor is not operating.
See Standard A/C Electrical Troubleshooting, page 17.
Louver Temperature
1. Record the ambient temperature and relative humidity away from the tractor.

7000 - 45
2. Put a thermometer the right uppermost front console louver and run the compressor for 10 minutes to
make sure the system has stability (per conditions listed below chart).
3. Compare the thermometer reading and ambient temperature reading to the chart. If the reading is higher
than the values in the chart:
The heater control valve is not closing.
The system may need refrigerant.
There is a restriction in the system.
The compressor is not operating.
Evaporator air is bypassing the core. See Plenum Sealing.
Thermal expansion valve malfunctioning.
4. Go to gauges and testing A/C Troubleshooting Foldout and Air Conditioning System Service Section for
further internal troubleshooting.
Louver Temperature Chart

Ambient Louver Temperature*
Temperature
Low RH High RH
21°C 6°C 16°C
(70°F) (43°F) (60°F)
27°C 9°C 19°C
(80°F) (49°F) (66°F)
32°C 13°C 22°C
(90°F) (56°F) (72°F)
38°C 17°C 26°C
(100°F) (63°F) (78°F)
43°C 21°C 29°C
(110°F) (70°F) (84°F)
48°C 24°C Data Not Currently
(120°F) (76°F) Available
* Temperatures shown are highest normal temperatures expected; actual mid-cab louver temperatures
may be cooler. The louver temperature chart is based on the following conditions: (1) Engine operating at
1500 RPM. (2) No engine load. (3) Blower control in the highest speed position. (4) Door and service door
open. (5) Air conditioner temperature control set to maximum cooling. (6) Air conditioner control switch set to
ON (CCM) or DEFOG/DEFROST (ATC) mode. (7) Mode door control adjusted to mid-cab vents only, fully
counterclockwise. (8) Gauge readings taken 15 minutes after start up. (9) Hood closed. (10) Heater lines
(supply and return) clamped at the engine. (11) All cab air vents open.

7000 - 46
HOSES AND HEATER CONTROL VALVE

Compressor Hoses
1. Make sure that all hose and line connections are properly torqued.
2. Check hoses for bends or cracks. Replace all hoses that have damage.
Heater Hoses
1. Position temperature control in maximum cooling
position (full counterclockwise). Start engine and
warm up.
2. Feel the heater core hose tube connections (Item 1) 1
to see if they are hot.
3. The heater control valve in the cab is not working if
the core tube connections are hot from engine cool-
ant.
RD99N052
Heater Control Valve

When power is applied and the system is on, the heater
control valve (Item 1) will adjust to the position required to
achieve the current cab temperature set point. To confirm
proper valve operation, adjust the cab temperature control
to the maximum heat position. The slot in the top of the
servo motor actuator can be observed to rotate. Cycling
the power off and back on will cause the valve to return to
the off position and back open. If while the system is off,
or in maximum cooling mode, the heater tube connections
at the heater/evaporator core are hot, heater control valve 1
malfunction may be occurring.
1. Use a vise clamp on the heater supply line to stop the
flow of coolant through the heater/evaporator core.
2. Check the heater/evaporator core tubes again. RD99N053
3. Check the cab air louver temperature.

4. If temperature decreases, check to see if there are any ATC fault codes displayed.
5. Check for 12V supply on terminal 10 at the control valve actuator. Check for a varying signal to the actuator
on terminal 8 while adjusting the temperature control. If signal variation is not detected, problem is with
ATC controller.
6. Replace the valve if the controller checks out but leakage through the heater valve is detected.

7000 - 47
EVAPORATOR AND PLENUM CHECK

Evaporator Core
1. Incline the operator’s seat forward. See ACCESSING
THE A/C UNIT, page 12.
2. Check the fins on the evaporator. All the fins that have
bends or damage must be straightened.
3. Keep the evaporator/heater core (Item 1) clean. If the
core is dry, use compressed air or a vacuum cleaner.
If the core is wet, flush the core with water using a
hose without pressure. Make sure the water drains
freely from the condensate drain tubes.
4. If the evaporator is extremely dirty, check the condi-
tion of the cab filter hose and cab door and service 1
door seals. See CAB PRESSURIZATION TEST in
the Air Conditioning System Service Section. RD99N158
Plenum Sealing
5. Correct plenum sealing will permit air through the evaporator but not around the evaporator. Check two
foam seals at bottom of core and check that drain pan is sealed against floor plate.
6. Check that condensate drain check valves are installed.
7. Reinstall the operators seat.
Filters
1. Keep the air filter element (Item 1) clean to provide
maximum air flow into the operator cab. See Air
Conditioning System Service Section in this manual
for complete instructions. Make sure filter seal is not
damaged.
2. Keep the cab recirculation filter (located behind the
operator seat) clean to provide maximum filtering of
recirculated air inside the cab. See Air Conditioning
System Service Section in this manual for complete
instructions.
1
RD99N155

7000 - 48
CAB AND EVAPORATOR TEMPERATURE SENSORS

Cab and Evaporator Sensor Resistance versus Temperature
200
180
160
140
Resistance (Ohms,000)
120
100
80
60
40
20
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Temperature (°F)
RH00H071
Both temperature sensors have the same resistance vs.

temperature response even though they look dramatically
different. Both sensors should measure 20-25K ohms at
room temperature for normal operation.
If cab temperature sensor (Item 1) failure occurs, the
controller supplies a default cab temperature value of
68°F (20°C); and an ATC fault code 08 displays.
Depending on set point the compressor will engage and
cool the cab, or the heater control valve will open and
warm the cab. The operator must assume manual control
of temperature and may wish to assume control of blower 1
speed. The operator must decrease the set point to less
than 66°F (18.8°C) to engage the compressor or increase
the set point to greater than 70°F (21°C) to open the Cab Temperature Sensor
heater control valve. This will supply the 2°F (1.1°C)
RD99N055
difference between the set point and the supplied cab
temperature value which the controller needs to drive to
and maintain set point.

7000 - 49
If evaporator temperature sensor failure occurs, the compressor will not engage and an ATC fault code will
display - 10 for an open circuit condition and 11 for a short circuit condition. Temperature sensed for fault code
10 is -2°F (-19°C) at the evaporator, and this is why on extremely cold days at start-up, code 10 displays until
evaporator temperature exceeds this value. Temperature sensed for fault code 11 is 180°F (82°C)
Both sensors are thermistors - thermal resistors. With these thermistors the colder the environment, the
greater the electrical resistance; and the warmer the environment, the less electrical resistance. For code 10,
at -2°F (-19°C) the thermistor senses maximum resistance, which the controller interprets as actual
temperature or an open condition and locks out the compressor. For code 11, at 180°F (82°C), the thermistor
senses minimum resistance, which the controller interprets as short circuit and locks out the compressor.
These sensors can be failing without generating a fault code. Measure the resistance of the sensor and your
ambient temperature, and compare the readings to the Resistance versus Temperature chart on page 48. If the
readings vary from the chart by more than 3%, replace the sensor.
See “Evaporator Temperature Sensor and Circuit Test (Standard A/C)” on page 29.
The evaporator temperature sensor (Item 2) must be installed 4.2
inches (107 mm) (Item 1) from the left hand rear side of the evaporator. 1
The sensor must be installed below the second refrigeration tube row
at a 30° downward angle. Be careful not to kink the sensor. Insert the
sensor in the evaporator core (Item 3) up to the angled section.
3
Evaporator Core
(Rear View)
RH99D218
3
2
RD99N056

7000 - 50
CAB PRESSURIZER BLOWER

1. Listen for the pressurizer motor to start when the engine is
running at greater than 500 rpm. The cab pressurizer motor
is accessed under the instructional seat in the cab behind
the trim panel. It draws air from the vents in the cab cap
through the left hand rear post through the cab filter and
feeds it directly to the A/C unit under the operators seat.
2. The cab pressurizer blower relay is located in the fuse and
relay compartment on the right hand side of the operator’s
seat.
3. With the engine running at greater than 500 rpm if the motor
does not run, check voltage at red feed wire - 92 (R). If no
voltage, check fuse 32 (15 amp) on fuse block 262. If 12V
present (normal), check ground. If all above conditions are
met, replace blower motor. See “Cab Pressurizer Blower
Relay Supply & Ground Test (Standard A/C)” on page 33.
RI99N002

8000
Section 8000
CONTROLLER SYSTEMS

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. Controller Systems
8000 - 3
TABLE OF CONTENTS
DICKEY-JOHN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
TOPIC 1 - COMMON OPERATING QUESTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Granular System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Liquid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
TOPIC 2 - BASIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Display Does Not Turn On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Short in System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Error Message Cannot be Cleared. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
System Does Not Operate in Auto, Only in Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
System Does Not Operate in Auto or Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
TOPIC 3 - SYSTEM SENSORS AND ACTUATORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Checking the Switch Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Checking the Ground Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Checking the Lift Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Checking the Application Rate Sensor (Granular) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking the Hydraulic Control Valve (Granular) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Checking the Liquid Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Checking the Fan RPM Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Checking the Hopper Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Checking the Pressure Transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
TOPIC 4 - CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting the Wrap Around Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Running the Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TOPIC 5 - HARNESSES AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Console and Harness Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Locating a Shorted Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Locating An Open/short Within A Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Sealing the Repaired Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
RAVEN SCS 460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Common Conditions And Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Procedure to Test Speed Sensor Extension Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Procedure To Test Flow Meter Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Flow Meter Maintenance And Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Procedure To Re-calibrate Flow Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

8000- 4
MID-TECH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SPRAYER ERROR MESSAGES (COMMON CONDITIONS AND SOLUTIONS) . . . . . . . 23
Err 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Err 1, Pump L (Pump F for TASC 6300/6600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Pump 1, 2, 3 (TASC 6300/6600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Err 2 (Flashing “Too Slow”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TASC 6300/6600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Err 3, Pump L (Pump F for TASC 6300/6600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump 1, 2, 3 (TASC 6300/6600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Err 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Pump 1, 2, 3 (TASC 6300/6600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Err 5, Pump L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Err . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Err E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
OFLO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Err L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Err C, n hook (backward 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
US, Metric and Metrish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
HOLD/CLOSE Of The Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manual Override - ARC 6000/TASC 6100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manual Override - TASC 6300/6600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Sprayer Prime Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ARC 6000 CONSOLE DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
TASC 6100 CONSOLE DEFAULTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
TASC 6300/6600 CONSOLE DEFAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
CONSOLE PIN OUTS AND NORMAL VOLTAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
FLOW CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
PROCEDURE TO VERIFY SIGNALS FROM THE RAVEN FLOW METER . . . . . . . . . . . . 34
Procedure To Test The Flow Meter Sensor Output To The ARC Console. . . . . . . . . . . 34
Verifying The Acre Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Verifying The Operation Of MID-TECH Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . 35
SPX / MID-TECH WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Case IH Supplied Speed Sensor And Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Case IH Supplied Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
AUTO-RANGE® SYSTEM PLUMBING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
BY-PASS VALVE SYSTEM PLUMBING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

8000 - 5
REVERSE VALVE DRIVER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
401-0027/405-0113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
9 BOOM INTERFACE WITH IS/GSO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
405-0156/78-0501 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
AUTO-RANGE® VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SERVICE SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8000- 6
DICKEY-john
TOPIC 1 - Common Operating Questions
This topic lists a series of frequently asked questions. These are grouped by subject to provide easy reference
in setting up your system for optimum operation. Often basic terms prove to be the point of confusion which
can be cleared up with a little more information. Reading the following should aid your understanding of overall
system operation.
Granular System
Interchanging Parts
Question: Can GC1000 or CCS100 parts be reused in a Land Manager® system?
Yes, the radar and the hydraulic control valve with the use of a valve driver are directly interchangeable. The
application rate sensor can be used with the correct adapter cable.
Using Spinners
Question: Does the console control the spinners as well as the conveyor/belt?
No, the spinners are controlled manually.
Tests Calculations Disagree

Question: I did two different drop tests and used the two formulas described in the Operator’s manual
for determining spreader constant. The results calculated were two completely different numbers for
spreader constants. What did I do wrong?
Be sure that the correct values are being used for each formula. All the formulas will yield identical numbers.
Mounting Application Rate Sensor

Question: Can the application rate sensor be mounted on a conveyer shaft or must it be installed on
the conveyer motor?
The rate sensor can be installed on any shaft that rotates in proportion to the conveyor travel rate.
Need to Recalculate
Question: Does a spreader constant require recalculating if the rate sensor is moved to a different
shaft?
Yes. However, the shaft used on must rotate smoothly with application of product.
Under-applying
Question: I have discovered that I am under-applying just a little. Is there a way to fine tune the
system?
Simply adjust the spreader constant the same percentage as your application error. Adjust up to increase the
application rate; down to decrease. This works if the error is within 10%. Larger errors may indicate other
problems.
Other Problems
Question: What are some other problems?
Larger application problems are normally traced directly to programming errors, wrong gate setting, incorrect
ground speed signal, or a faulty rate sensor.

8000 - 7
Conveyor Surging
Question: The conveyor on the truck has recently started surging. The hydraulics seem to be normal.
What could cause the problem?
Make sure the rate sensor is not rocking back and forth on its mounting. Also check to see the coupling is not
slipping on the rate sensor shaft.
Liquid System
Parts Interchangeability
Question: Do any SC1000 or CCS 100 parts work with the Land Manager®?
Yes, the SC1000 hydraulic valve with driver, pressure sensor, radar, and all other CCS 100 components work
with the Land Manager® system.
Zero Pressure Calibration

Question: Do I have to do the Zero Pressure Calibration each time I fill the tank?
No. Set it once and forget it unless the pressure on the boom does not match the console.
Abnormal Pressure Display

Question: After installing check valves on my sprayer, the console indicates pressure when I’m not
spraying. Why?
This is common on machines with check valves, no drip nozzles, air stops, etc. These systems continue to hold
pressure on the boom and due to the pressure at the sensor cause a display reading all the time - even if you
are not spraying. It is also important to note that large changes in barometric pressure and temperature could
cause a significant shift.
Definition of Capacities
Question: Please define Nozzle Pressure and Nozzle constant?
These two setup positions describe what nozzles you are using. Simply stated, the Nozzle Pressure is only a
pressure reference, any pressure will due. The Nozzle constant is how much water in gallons flow out of that
nozzle in one minute at that pressure reference. From these two numbers, the console determines the flow rate
from that nozzle at any given pressure.
Nozzle Pressure
Question: Does the pressure entered in Nozzle Pressure have to match the pressure being sprayed? Is
there an ideal pressure that I can use?
No it does not. You can enter any pressure that you like into Nozzle Pressure, however it is best to use a
pressure that is within the working limits of the nozzle you have selected. There really is no ideal pressure, but
40 PSI is probably the most popular choice. Just remember to use the correct flow rate for the pressure
selected.
Under Application
Question: My applicator has XR8004 nozzles with 20” spacing on two booms. I’m using 40 for Nozzle
Pressure and.4 for Nozzle Constant. My pressure sensor is mounted between the Dj valve and the
boom shutoff valves. I have found that I am under-applying. What is wrong and how do I correct the
problem?
What is being seen here is a difference in pressure between the pressure sensor and the nozzle. Pressure
drops occur in any sprayer, and the distance from sensor to nozzle determines the amount of the loss. In this
case, the system is controlling the application based on the pressure at the sensor, but the nozzles with a lower
pressure are under-applying. To correct this problem either move the sensor to the boom next to a nozzle, or
do a catch test at the pressure that you have entered into NOZZLE PRESSURE. Catch a few nozzles on each
boom, average the results, and enter the average flow rate per gallon as your Nozzle Constant. This method
compensate for pressure losses that may be occurring.
8000- 8
Valve Full Open Alarm
Question: I’m getting the alarm before the upper pressure limit is reached. What is causing this?
The alarm means the control valve is fully open. This indication normally occurs when the pressure
requirement is greater than the system can produce. However, a damaged pressure sensor or actuator can
also be the cause. To eliminate the sensor, check the pressure on the console against the manual gauge on
your boom, if you have one. If the pressure on the manual gauge is greater than the console pressure, check
the sensor. If the console and manual gauge match, then the sprayer is unable to develop the correct pressure.
Check to see the actuator is opening completely. Then check for slipping pumps, hose restrictions, sparge
valve open too far, etc.
Speed Range Display

Question: When setting my pressure limits, the speed ranges displayed are very high (or low). How do
I fix this?
Check your Nozzle Constant. It is either too high or too low. Also be sure you don’t have a misplaced decimal
point.
TOPIC 2 - BASIC SYSTEM

This topic lists a few basic problems to check before calling for assistance. The list below is not in any particular
order. Scanning through these possible problems may suggest a corrective action for returning the system to
normal again. If the problem cannot be solved, call Dickey-john for assistance.
Display Does Not Turn On.

Blown fuse
Check fuse in positive battery harness lead and replace with proper size fuse, if blown. If it blows again, check
for a shorted sensor lead or a damage cable (See below).
Fuse OK
If the fuse is normal, the indication is no current is being drawn. Check all connections to ensure good contacts
at the connectors. Inspect the battery connections very carefully and clean contacts as necessary.
Short in System.
Fuse blows immediately
To isolate the problem, disconnect all sensors and Main cable, but not the Power/RS 232 cable. This cable is
necessary to supply battery power to the console. Replace the fuse.
Fuse continues to blow

The console or Power/RS 232 cable contains the short. Disconnect the cable and check with an ohmmeter. If
no short is found in the cable, replace the console.
Fuse no longer blows

After disconnecting all sensors and cables, except battery and the fuse does not blow, the short is indicated in
the disconnected cables or one of the sensors. With power on, reconnect the Main connector and then each
sensor cable one at a time. When the fuse blows again, that sensor or cable contains the short (See correct
harnessing diagram to trace the wiring).

8000 - 9
Error Message Cannot be Cleared.
Damaged sensor or incorrectly installed
Correct installation or repair/replace the sensor.
Sensor not receiving +12 Volts
Check for +12 Volts at the sensor (See correct harnessing diagram). If voltage is not present, check cable for
damage or a faulty connection.
Signal line (GRN wire) is open or shorted

Check the green wire for continuity or a short from the sensor back to the console.
Application Rate or other Sensor is defective

If the above checks do not reveal the problem, replace the respective sensor.
System Does Not Operate in Auto, Only in Manual

Ensure the ground speed signal is present
If the ground speed indicates on the display, check the switch module and then suspect a faulty console.
No ground speed signal is present

Unplug the radar unit and check for +12 Volts at the radar cable connector (See correct harnessing diagram). If
no +12 Volts is present, check continuity of the cable or observe for damage. Repair or replace as required.
No ground speed signal is present on the GRN wire

Check the Fg (GRN) pin from the sensor back to the console. If continuity is absent or cable is shorted, check
the connections at the connector or suspect a damaged cable.
Signal is not present at the sensor

Replace the radar sensor and try again.
Cable and sensor are normal

Replace the console.
System Does Not Operate in Auto or Manual

Console Programming may be incorrect
Be sure the channel is turned on. Then check BOOM CONFIG (+12V ON/OFF) under the CONFIG MENU.
Also check the operation of the implement switch.
Check Master Switch Module cable and switch

Ensure continuity from the connector and the module is present. Also ensure no shorts between conductors
exist. Check the switch for correct operation.
Check main cable wiring

Check the wiring between the Master Switch Module and the console. Check for open or shorted conductors
(See Wiring Diagram).
Check the valve actuator

Check for correct voltages and signals to the actuator (See Wiring Diagram).
No +12 Volts is present to the actuator

Check the power cable and the signal wires to the console.

8000- 10
TOPIC 3 - SYSTEM SENSORS AND ACTUATORS

During normal system operation, the alarm and console display indicates the status of the system sensors and
product application devices. If a failure occurs, the operator is alerted and the problem can be quickly identified.
Before calling for assistance, check the following list to locate and repair the failure.
Checking the Switch Module

This device consists of only the cable and a three position switch.
From the console, select SYSTEM mode, SERVICE menu, TROUBLESHOOTING menu and finally LOW
LEVEL TEST
View the Master Switch as you change switch positions. If the response is not correct (OFF - 00, AUTO - 01,
Manual - 11), proceed with the next step.
Open the Switch Module and verify the switch operation. Panel Off/Auto/Manual
Use an ohmmeter to verify the switch contacts. Check each Side Switch
switch position.
Figure 1. Checking the Master Switch
Visually inspect the cable for damage. Use the ohmmeter

to check integrity of the cable.
Ty-Straps
Check the cable for shorts between wires and then check each
wire for an open condition.
Checking the Ground Speed Sensor

One of three types of Ground speed sensors may be used; (1) radar sensor, (2) in-line speedometer drive
sensor or (3) magnetic distance sensor.
Begin by visually inspecting the cable and sensor for damage. Check all connections and inspect
sensor mounting.
When inspecting a radar sensor, check for excessive vibration. Start the vehicle engine and slowly
increase engine RPM to the governed rate or operating RPM while observing the console display.
The display should remain at zero. If not, the radar mounting is not secure.
If no ground speed value displays during operation, check the condition of the harness.
A simple test can be conducted to prove harness integrity to the console by using a small jumper wire.
Disconnect the ground speed sensor from the main harness. At the main harness connector, identify each pin.
Fashion a jumper wire between the ground line and the signal line of the cable. Be sure not to short the +12
volt line to ground. Doing so results in blowing the main system fuse. Intermittently make and break the
connection between the ground and the signal lines as rapidly as possible. The results are a series of random
pulses which should generate some speed indication on the display. If the display responds, the system
harness and console are normal indicating the ground speed sensor is at fault.
If using a magnetic distance sensor, check the sensor with an ohmmeter.

Connect the ohmmeter directly across the sensor element. The reading should be infinity when the magnet is
away from the sensor and zero ohms when the magnet is next to the sensor. Also, a click should be heard
when a magnet is passed near the sensor.

8000 - 11
Checking the Lift Switch
The micro-switch closure integrity can be checked with an ohmmeter.
Disconnect the lift switch from the harness at the connector.

Connect an ohmmeter across the terminals of the lift switch and manually open and close the switch.
The ohmmeter should show near zero resistance when the switch closes and infinity when open.
Checking the Application Rate Sensor (Granular)

The application rate sensor is mounted on the drive shaft of the conveyor to
monitor the rotational rate of the shaft.
If no application rate displays during operation, check the condition of the harness.
A simple test can be conducted to prove harness integrity to the console by using a small jumper wire.
Disconnect the application sensor from the main harness. At the main harness connector, identify each pin.
Fashion a jumper wire between the ground line and the signal line of the cable. Be sure not to short the +12
volt line to ground. Doing so results in blowing the main system fuse. Intermittently make and break the
connection between the ground and the signal lines as rapidly as possible. The results are a series of random
pulses which should generate some indication on the display. If the display responds, the system harness and
console are normal meaning the application rate sensor is the cause.
Checking the Hydraulic Control Valve (Granular)

The hydraulic control valve regulates the conveyor speed electrically via the console. If any of the spreader
components, such as the hydraulic pump or hydraulic motors are not operating properly, the control system
may appear to be faulty. Check that all the mechanical devices are operating normally before suspecting any of
the control system components.
Check that the valve operates in the manual mode.

If not, disconnect the cable to the actuator driver circuits and measure for drive signals.
If no signals are present on the three lines, suspect the cables first and then the console. If signals are
observed on the lines, try a new valve driver actuator. If the control system functions normally in the MANUAL
mode but does not open in the AUTO mode, the problem may be a faulty ground speed input.

8000- 12
Checking the Liquid Control Valve
The liquid control valve controls the liquid flow rate for field application. If the control system is not functioning
correctly, first check the functionality of all other system mechanical devices.
Check to make sure the ground speed sensor is functioning.

Check the functionality of the pressure transducer on a sprayer system or the flow meter on the
anhydrous system.
Check to be sure the control valve is operating in the manual mode.
Solicit the aid of an extra person. Hold the switch on the switch module in the MANUAL position. The control
valve should be heard opening for approximately 1.5 seconds. Release the switch; the control valve should
close in 1.5 seconds. If the motor in the valve is not running, then the control valve actuator or the cabling is
defective.
Checking the Fan RPM Sensor

Check the fan sensor by waving a piece of metal quickly back and forth across the sensors end while observing
the console display. Some reading should be observed. Assuming the cabling is normal, no reading indicates a
faulty sensor.
Checking the Hopper Level Sensor

A sensor failure is first detected at the console by an improper readout. If this occurs try unplugging the sensor.
If no change occurs, check the cabling. If it does change, replace the sensor. If the display message is simply
indicating low too soon or not soon enough, inspect the mounting position of the sensor.
Checking the Pressure Transducer

Before checking a pressure sensor, release all the pressure from the lines or completely remove the sensor
from the boom and then perform a Zero Pressure Calibration. If the constant comes up.0000, check for +12
volts at the sensor connection on the harness and also check continuity on the green wire from the sensor
connection to console connection (See Wiring Diagram). If +12 volts is not present, check continuity of the
power and ground wires. If all harness checks are normal or if the Zero Pressure Calibration constant reads
1.000 or more, replace the sensor.

8000 - 13
TOPIC 4 - Console
During troubleshooting, the ability to quickly verify console performance becomes very important in isolating
system failures. Console operation can be proven either by substituting a different console or by using a special
wrap around cable (test module). The wrap around cable allows a special self test routine to check normal
console operation. If the test proves normal, the console is eliminated as a possible cause and troubleshooting
can proceed to the harness and other system components. If the tests fail, remove the console from the
system and tag for immediate repair.
Connecting the Wrap Around Cable

The wrap around cable is a small black box with three sets of cables with connectors. The two large connectors
replace the harness connectors at the bottom of the Land Manager® and are keyed to prevent reversal. The
third cable containing a fuse link connects to +12 volt power or battery. When power is turned on, the Land
Manager® recognizes the presence of wrap around cable and automatically begins testing.
Wrap Around Box
Positive Negative
Battery Battery
Terminal Terminal
Running the Test

After applying power, each test automatically runs. When complete, either a FAILURE or PASS displays with a
prompt to press ENTER. If sufficient failures occur to fill the screen, “MORE” displays at the top of the list.
Errors on a previous screen cannot be reviewed from the display.
After all functional tests finish, a keypad test screen appears to allow dynamic testing each key on the front of
the console.
Connect J1 and J2 to the console connectors.

The connectors cannot be inserted incorrectly.
Connect the power cable to a +12 Volt source.

The red wire connects to the positive terminal, the black wire to the negative terminal.
Turn the power on using the I/O button on the console.

The console starts by displaying the DICKEY-john logo and sounding a beep. The next screen appearing reads
“FUNCTIONAL TEST”. The tests automatically follow.
When finished, observe the results.

a. If the display indicates “PASS”, the console is functional and ready for operation. Proceed to next step.

8000- 14
b. If the display indicates “FAILED”, disconnect and tag the console for repair.
Depress ENTER to continue with the key pad test.
The screen displays three statements; KEY PAD TEST, PRESS KEY TWICE TO END TEST, and TEST KEY
NO KEY PRESS.
Depress each console key once except the I/O button.

Each key should show an appropriate response on the display (i.e. depressing the CLEAR key should display
“CLEAR”).
When finished, end the test by depressing any key twice.

The screen displays “TEST COMPLETE”. Remove power and disconnect the wrap around cable.
Topic 5 - Harnesses and Repair

Most cable failures are categorized as either a “short” or “open” circuit. If a either condition occurs within a
cable, locating the actual fault can be tedious and frustrating. When encountering an intermittent break,
locating the problem may be difficult but ultimately must be treated as an open circuit. After locating the break
or short, cable replacement should be planned but temporary repair can be performed in order to continue
working. In repairing, a good splice and a weather- tight seal is extremely important. The following paragraphs
describe how to locate cable faults and then repair properly.
Console and Harness Layout

Before commencing wire tracing from the console to the sensors, take a moment to study the general wiring
scheme. Refer to the correct wiring diagram in the fold-outs of this manual. Study the general wiring layout from
the console to each sensor and particularly the wire colors to the sensor in question. Each sensor generally
uses a RED wire for +12 volt power, a BLK wire for ground and a GRN wire for the signal line. The power lines
from most sensors connect to a common junction point within the harness while the signal lines are unique to
each sensor and run separately to the console.
Locating a Shorted Cable

A shorted sensor cable renders the sensor inoperative or may cause system failure by blowing the main power
fuse. Three basic types of shorts may appear within a sensor; (1) power to ground, (2) power to signal, and (3)
signal to ground.
To locate a power/ground short;

Check the main power and actuator fuses.
If the a actuator fuse(s) is blown, the short is isolated to that actuator cable or actuator. Unplug the actuator
and try another fuse of proper size. If the fuse blows again, the actuator cable is shorted. If not, the actuator is
shorted.
If the main power fuse is blown, proceed to Next Step.
Unplug the main cable (J1) from the console and install a new fuse.
If the fuse blows again, the short is either in the power cable or the console. Disconnect J2 from the console
and repeat the test with a new fuse. If the fuse blows, the cable has a short; if not, the console has an internal
short.
If both the cable and console prove normal, proceed to Next Step.
Unplug all the sensor and extension cables and install a new fuse.
If the fuse blows with all sensors and extension cables disconnected, the short is isolated to the main harness.
Begin reconnecting each connector one at a time.

8000 - 15
When the line containing the short is connected, the fuse blows again. Investigate that cable for the short. To
locate the actual short, proceed as follows.
To locate a signal line short;
A sensor signal line can be shorted to either to ground or to +12V but does not normally blow a fuse. Either
condition renders the sensor inoperative. If only one sensor is inoperative, the short must be within that sensor
or its cable. If more than one sensor is inoperative, the problem is closer to the console and the main cable
should be suspected.
To isolate, proceed as follows;

Turn off system power and disconnect the failed sensor.
Measure the resistance between the pins at the connector of the sensor.
Readings of less than a few hundred ohms should be investigated as shorted conductors.
If previous step indicates a normal sensor, check the main cable.

Readings between the sensor line and ground or the sensor line and power should measure a high resistance.
If not, disconnect the main cable from the console and repeat the test. If the condition persists, the cable is
shorted.
To locate an open line;

An open line (+12V, Gnd, or signal) also renders a sensor(s) inoperative. If only one sensor is inoperative, the
open must be within that sensor or its cable. If more than one sensor is inoperative, the problem is closer to the
console and the main cable should be suspect. To isolate, proceed as follows;
Disconnect the faulty sensor.

Measure resistance between the power, signal, and ground leads.
A high resistance should be measured between each check but should not indicate a short.
Turn the console on and measure voltage between the +12V, signal, and ground leads of the main
cable.
A +12V reading between the power and ground terminals indicates those two lines are normal. Some small
voltage should be read on the signal line. No reading indicates the signal line is open if the power and ground
leads have been verified.
Locating An Open/short Within A Cable

Carefully inspect the cable for damage.
Observe cable for loose wires, particularly at the connectors.
Check along the cable for a mangled area caught in the machinery or by sharp objects piercing the
cable. If a damaged area is found, proceed to Step 6.
If no damage is observed, disconnect the cable at both ends. Use an ohmmeter to check for shorts
between conductors.
Check for shorts between all combinations of conductors. The simplest method is illustrated below using an
example with a five conductor cable. At one of the connector ends, measure resistance between pins in the
following sequence:
1 to 2 2 to 3 3 to 4 4 to 5
1 to 3 2 to 4 3 to 5
1 to 4 2 to 5
1 to 5
By progressively moving through the pin count, no combination of conductors is missed. No continuity should
be found in any measurement.

8000- 16
Check for an open condition by folding the cable in half so that the two connector ends lay side by
side.
Check for continuity through each conductor. Use wire colors or harness drawings to identify the correct
conductor. If the cable is not easily folded in half because of being strapped down, short pins together at one
connector with a small wire jumper and check for continuity through the two conductors at the other connector.
Repeat until all conductors are verified. If a break is found, isolate it to a single conductor.
Locate the break within a wire.

Connect one lead of an ohmmeter to each end of the suspected broken wire. Move along the harness flexing
the cable by hand while observing the ohmmeter for an indication. A response indicates the damaged area. If
an area cannot be determined, select the center. Use a sharp object such as a straight pin or knife tip to pierce
through the insulation. It may be necessary to carefully slit the outer jacket of the cable to reach the suspected
wire. Remember, the opening later requires repair. If the cable is strapped down, add a length of wire to one
ohmmeter lead to lengthen its reach.
Determine which cable half contains the break.

Check continuity between the pierced point and the cable connector. If no continuity is present, move the
ohmmeter lead toward the connector (i.e. half way). When continuity is obtained, the break is between the last
two readings. Finalize by working toward the break until the exact location is pinpointed.
Sealing the Repaired Cable

A damaged or cut cable can be repaired in the field using the following procedure. This type of repair is limited
to cables only. Do not attempt to repair any wiring inside the hydraulic control valve, the ground speed sensor,
or the application rate sensor. Doing so breaks the seals and voids the warranty. Do not attempt to repair cable
connectors. The following method of repairing cables is for temporary use only. Units with new cables or new
extension cables must be ordered as soon as possible, otherwise chemicals may enter the repaired area and
damage components. Always use rosin core solder for making cable repairs. NEVER USE ACID CORE
SOLDER!
Carefully cut away the cable cover at the damaged area.

Strip about 1/2 inch of insulation from damaged lead(s). Do not cut the wire strands. Clean about two inches of
the cable cover and wire ends.
Twist the two bare leads together, solder, and tape for each damaged lead.
Be certain to match wire colors. Then solder the leads. Tape each repaired lead with vinyl electrical tape.
Figure 3. Taping each lead
Add a layer of vinyl electrical tape up to the cable cover at each end of the repaired section.

8000 - 17
Make paper trough, as shown in Figure 4, then apply silastic compound over the repaired section. Be sure to
use enough silastic compound to fill the open ends of the cable.
Figure 4. Sealing the Repair
Allow silastic compound to dry, then use vinyl electrical tape to completely cover the repaired area.
Apply tape to at least two inches beyond each end of the cable opening. Secure repaired cable in a manner to
protect the damage from reoccur-ring.
Tape Final Repair.

This procedure is intended only for temporary repair. Replacement of the complete cable is highly
recommended. Failure to do so may result in damage to the system since active chemicals can creep up
through the cable and into one or more of the system units.
Figure 5. Final Wrapping the Repair.

8000- 18
RAVEN SCS 460

Common Conditions And Solutions
No Display Lights With Power On.

1. Check fuse on back of Console.
2. Check battery connections.
3. Check operation of POWER ON/OFF switch.
4. Return Console to your Dealer to replace Processor Board Assembly.
All Keyboard Lights On At Same Time.

1. Return Console to your dealer to replace Face Plate Sub-assembly.
A Digit Cannot Be Entered Via Keyboard.

1. Return Console to your Dealer to replace Face Plate Sub-assembly.
An Indicator Light On A Key Will Not Illuminate.

1. Return Console to your Dealer to replace Face Plate Sub-assembly and/or Processor Board Assembly.
Console Displays Flashing “Cal” Whenever Vehicle Engine Is Started.

1. Check battery voltage and battery connections.
Console Displays Flashing “Cal” Whenever Master Switch Is Turned On Or Off.

Console Displays Flashing “Cal” Whenever Speed Is Changed.

“Time” Function Is Inaccurate Or Drifting.

1. Return Console to Dealer to replace Processor Board Assembly.
One Display Digit Has One Or More Missing Segments.

1. Return Console to Dealer to replace LCD Display Board Assembly.
Speed Display “0”.

1. Check Speed Sensor cable connector and plug on back of Console for loose pins.
2. Clean pins and sockets on Speed Sensor cable connectors.
3. If no extension cable is used, replace Speed Sensor Switch Assembly.
4. If Speed Sensor Extension Cable is used, See page 8000-20

8000 - 19
Speed Inaccurate Or Unstable (Wheel Drive Speed Sensor).
1. Run speed check on hard surface road. If SPEED is accurate, investigate Speed Sensor on different
wheel.
2. Remove one red magnet and one black magnet from the wheel. (Reposition remaining red and black
magnets directly across from each other). Enter a SPEED CAL number in the Console twice as large as
the correct SPEED CAL number. Run speed check on hard surface road. Remove these two magnets and
replace with other two. Run speed check. If SPEED is in accurate with only one set of magnets, replace the
bad set. If SPEED is inaccurate with both sets, replace Speed Sensor Assembly.
NOTE: Re-enter original SPEED CAL number after testing is complete.
Speed Inaccurate Or Unstable (Speedometer Drive Speed Sensor).

1. Wiggle cable at the Speed Sensor connector. If speed is displayed, tighten connector or replace
Transducer Assembly.
2. Check Speedometer Cable Adapter, Key, and Transducer Assembly for proper connections and
engagement.
3. Check for kinks or sharp bends in speedometer cable.
4. Replace Speedometer Transducer Assembly.
Rate Reads “0000”.

1. Verify SPEED is registering accurately. If SPEED is zero, refer to Troubleshooting Problem “Speed Display
0”.
2. Verify TOTAL VOLUME is registering flow. If not, refer to Troubleshooting Problem “Total Volume does not
Register”.
Rate Inaccurate Or Unstable.

1. Verify that all numbers “keyed in” Console are correct. Verify SPEED is registering accurately. If SPEED is
inaccurate, refer to Troubleshooting Problem “Speed Inaccurate or Unstable (Wheel Drive Speed Sensor)”
or “Speed Inaccurate or Unstable (Speedometer Drive Speed Sensor)”.
2. In MAN (manual) operation, verify that RATE display (GPA) holds constant. If not, refer to Troubleshooting
Problem “Total Volume Registers Flow Inaccurately”.
3. In MAN (manual) operation, check low end and high end pressure range. Pressure range must be per
initial system set-up in Raven Installation and Service Manual. If pressure cannot be adjusted manually,
refer to Troubleshooting Problem “Total Volume does not Register”.
4. If problem persists, return Console to Dealer to replace Processor Board Assembly.
Can Not Vary Rate In Manual Operation Or In Auto.

1. Check cabling to motorized Control Valve for breaks.
2. Check connections in cabling for cleanliness.
3. Verify that there is voltage at the valve connector by placing MASTER switch ON; RATE 1/RATE 2/MAN
switch to MAN; and POWER switch to ON. Manually operate INC/DEC switch to verify voltage.
4. Verify that valve is turning, if not, replace motorized Control Valve.
Sprayer Pressure Is Correct But Rate Is Low.

1. Verify that nozzle strainer screens or check valves are not plugged.
2. Verify that pressure at each boom is the same.
3. Verify all nozzles are of proper and same orifice size. See the Raven Installation and Service Manual.

8000- 20
Total Volume Does Not Register.
1. Check Flow Meter Cable for breaks and shorts. See page 8000-21 for test procedure.
2. Check internals of Flow Meter; clean and adjust. See page 8000-22 for Flow Meter cleaning and
adjustments.
3. Replace Flow Meter Transducer.
Total Volume Registers Flow Inaccurately.

1. Verify that arrow on Flow Meter is pointing in direction of flow.
Motorized Control Valve Rotates More Than 1/4 Turn.

1. Replace motorized Control Valve.
Water Inside Cover Of Motorized Control Valve.

1. Replace Isolation Flange Assembly and coupler shaft.
2. Replace entire motorized Control Valve, if PC board or motor is corroded and will not run.
Boom Solenoid(S) Will Not Operate.

1. Check cable for wires with breaks.
2. Check connectors for cleanliness.
3. Check BOOM switch and MASTER switch for operation.
4. Replace Boom Valves.
Procedure to Test Speed Sensor Extension Cables

Verify that the Console is in the SP1 Speed Sensor KEYWAY
mode while testing the cable. Disconnect extension
cable from Speed Sensor Assembly cable. Hold 10 O’CLOCK 2 O’CLOCK
extension cable connector so that keyway is pointing
in the 12 o’clock position.
Pin Designations
6 O’CLOCK
2 o’clock socket location is power.
10 o’clock socket location is ground.
6 o’clock socket location is signal.
Voltage Readings
1. 10 o’clock socket to 6 o’clock socket = +5 VDC.
2. 10 o’clock socket to 2 o’clock socket = +5 VDC.
NOTE: If a +5 VDC voltage reading is not present, disconnect the Flow Sensor cable. If the Speed reading is
restored, Test the Flow Sensor cable. See page 8000-21, “PROCEDURE TO TEST FLOW METER
CABLES”.

8000 - 21
Procedure To Check Cable
SPEED
1. Enter SPEED CAL number of 1000 in key labeled CAL
4
2. Depress key labeled
DISTANCE
3. With small jumper wire (or paper clip), short between the 10 o’clock and 6 o’clock sockets with a “short-no
short” motion. Each time a contact is made, the DISTANCE total should increase by increments of 1 or
more counts.
4. If DISTANCE does not increase, remove the section of cable and repeat test at connector next closest to
Console. Replace defective cable as required.
5. Perform above voltage checks.
6. If all cables test good, replace Speed Sensor.
NOTE: After testing is complete, re-enter correct SPEED CAL number before application.
Procedure To Test Flow Meter Cables KEYWAY

Disconnect cable from Flow Sensor. Hold Flow 10 O’CLOCK 2 O’CLOCK
Sensor cable so that the keyway is pointing in the 12
oíclock position:
Pin Designations 6 O’CLOCK

2 oíclock socket location is ground.
10 oíclock socket location is power.
6 oíclock socket location is signal.
Voltage Readings
1)2 o’clock socket to 6 o’clock socket = +5 VDC.
2)2 o’clock socket to 10 o’clock socket = +5 VDC.
NOTE: If a +5 VDC voltage reading is not present, disconnect the Speed Sensor cable. If the Flow reading is
restored, Test the Speed Sensor cable per Appendix “PROCEDURE TO TEST SPEED SENSOR
EXTENSION CABLES”.
PROCEDURE TO CHECK CABLE: METER

1. Enter a METER CAL number of one (1) in key labeled CAL
5
TOTAL
2. Depress key labeled
VOLUME
3. Place BOOM switches to ON.

4. With small jumper wire (or paper clip), short between the 2 o’clock and 6 o’clock sockets with a “short-no
short” motion. Each time a contact is made, the TOTAL VOLUME should increase by increments of 1 or
more counts.
5. If TOTAL VOLUME does not increase, remove the section of cable and repeat test at connector next
closest to Console. Replace defective cable as required.
6. Perform above voltage checks.
7. If all cables test good, replace Flow Sensor.

8000- 22
NOTE: After testing is complete, re-enter correct METER CAL numbers before application.
Flow Meter Maintenance And Adjustment Procedure

1. Remove Flow Meter from sprayer and flush with clean water to remove any chemicals.
2. Remove flange bolts or clamp from the Flow Meter.
3. Remove the turbine hub and turbine from inside Flow Meter.
4. Clean turbine and turbine hub of metal filings or any other foreign material, such as wettable powders.
Confirm that the turbine blades are not worn. Hold turbine and turbine hub in your hand and spin turbine.
The turbine should spin freely with very little drag inside the turbine hub.
5. If transducer assembly is replaced or if turbine stud is adjusted or replaced, verify the turbine fit before
reassembling. Hold turbine hub with turbine on transducer. Spin turbine by blowing on it. Tighten turbine
stud until turbine stalls. Loosen turbine stud 1/3 turn. The turbine should spin freely.
6. Re-assemble Flow Meter.
7. Using a low pressure (5 psi) [34.5 kPa] jet of air, verify the turbine spins freely. If there is drag, loosen hex
stud on the bottom of turbine hub 1/16 turn until the turbine spins freely.
8. If the turbine spins freely and cables have been checked per (See page 8000-21), “PROCEDURE TO
TEST FLOW CABLES”, but Flow Meter still is not totalizing properly, replace Flow Meter transducer.
Procedure To Re-calibrate Flow Meter

1. Enter a METER CAL number of 10 [38] in the key labelled
2. Enter a TOTAL VOLUME of 0 in the key labelled
3. Switch OFF all booms.
4. Remove a boom hose and place it into a calibrated 5 gallon [19 liter] container.
5. Switch ON appropriate boom switch (for the hose that was just placed into the 5 gallon container) and the
MASTER switch. Pump exactly 10 gallons [38 liters].
6. Readout in TOTAL VOLUME is the new METER CAL number. This number should be within +/- 3% of the
calibration number stamped on the tag of the Flow Meter.
7. Repeat this procedure several times to confirm accuracy. (Always “zero out” the TOTAL VOLUME display
before retesting).
NOTE: For greatest precision, set METER CAL to 100 and pump 100 gallons (378 liters) of water.
8. To verify Flow Meter calibration, fill applicator tank with a predetermined amount of measured liquid (i.e.
250 gallons). DO NOT RELY ON GRADUATION NUMBERS MOLDED INTO APPLICATOR TANK. Empty
the applicator tank under normal operating conditions. If the number displayed under TOTAL VOLUME is
different from the predetermined amount of measured liquid by more than +/- 3%, complete the following
calculation:
EXAMPLE:
METER CAL = 720 [190]
TOTAL VOLUME = 260 [984]
Predetermined amount of measured liquid = 250 [946]
Corrected METER CAL = METER CAL x TOTAL VOLUME

Predetermined amount of measured liquid
ENGLISH UNITS: METRIC UNITS:

= 720 x 260 = 749 = [190] x [984] = [198]
250 [946]
Corrected METER CAL = 749 [198]
9. Enter corrected METER CAL before resuming application.

8000 - 23
MID-TECH
Sprayer Error Messages (Common Conditions And Solutions)
NOTE: Check the battery connections, this is the most common fault.
Err 0
A required constant is set to zero.
1. Err 0, Pump L: reset flow meter Cal#.
2. Err 0, Dist Cal#: reset distance Cal#.
3. Err 0, Boom #: reset boom widths (including boom width C).
A calibration number or rate for one of the injection pumps is set to zero.
1. Check Calibration numbers and Target rates for each pump being used, to make sure a valve has been
entered.
NOTE: Sometimes this is caused by poor power connections at the battery.
Err 1, Pump L (Pump F for TASC 6300/6600)

Servo valve is fully open, traveling too fast for desired application.
1. Slow down, or check hydraulic flow to an hydraulically driven pump.
Nozzles too small for rate, speed and boom width. (pressure will read HIGH)
1. Change to larger nozzles.
Too much product being diverted to sparge.

1. Reduce sparging or turn up product pump output.
Strainer or nozzle screens plugged. (Pressure LOW, main strainer; pressure HIGH, nozzle screens).
1. Clean screens.
Servo valve is not responding.

1. Check at SPX fuse panel for a faulty fuse for valve. (Replace if necessary)
Pump 1, 2, 3 (TASC 6300/6600)

If displayed at normal operating speeds this may indicate a bad spot in the pump tubing which causes the
pump to stall.
1. Inspect tubing and replace if necessary. If replaced, re-calibrate pump before using.
Pump tubing to small.

1. Change to larger tubing.
Err 2 (Flashing “Too Slow”)

Not a diagnostic function in the ARC or the TASC 6100.
1. Contact MID-TECH if you see this message on these controllers.
TASC 6300/6600
Speed and rates too slow to deliver product accurately.
1. Speed up, change to smaller tubes or lower capacity pumps.

8000- 24
Err 3, Pump L (Pump F for TASC 6300/6600)
No flow in the product line.
Main product tank empty.

1. Refill tank.
Leak in main product line.

1. Check for ruptures or leaks at tubes, fittings, etc.
No output from main product pump.

1. Turn product pump ON.
2. Check for correct operation of hydraulic valves feeding the pump motor.
3. Check for air lock in the product pump, causing no output. Purge pump using the PRIME function.
Obstruction in main product line.

1. Clear blockage in product strainer.
Main flow control valve not opening.

1. Check Flow control/Boom connections on the back of the console. Secure if loose.
2. Verify that the boom valves are opening, may be a fuse or electrical connection problem.
3. Check that the AutoRange valve is opening (See ERROR 5)
Flow in the product line but no flow sensor signals registered.

1. Check for blockage of the flow sensor.
2. Test flow sensor and replace if faulty.
3. Check for broken or shorted cables between flow sensor and console.
Pump 1, 2, 3 (TASC 6300/6600)

Pump does not run at all. Rate sensor is generating no signals.
1. Check connections on back of console and for broken or shorted signal leads. Repair or replace as
necessary.
2. Check for power and ground at pump motor. If no power, check fuse, battery connections and pump driver
module.
3. Check for obstruction in the pump that may be keeping it from turning.
Pump runs for 10 to 15 seconds and stops. Console is receiving no signals from rate sensor.
1. Check connections on back of console.
2. Check pump sensor wiring, connections, and sensor clearance.
Err 4
Not a diagnostic function in the ARC or TASC 6100.
1. Contact MID-TECH if you see this message 0n an ARC or TASC 6100 controller.
Pump 1, 2, 3 (TASC 6300/6600)

Will shut down after 5 seconds of Err 4. If Err 4 corrects itself, system will recover by itself. If Err 4 doesn’t last
for 5 seconds, system will not be affected.
1. If pump is not running, check sensor for excessive vibration and sensor wire routing to make sure it is not
running near a source of electrical pulses which could cause false rate signals to the console.
2. Check battery connections.

8000 - 25
Err 5, Pump L
Application rate is exceeding the target rate by 15%. Valve is not responding.
1. Check at the SPX fuse panel for a faulty fuse for the valve. (Replace if necessary)
Often this is caused by loss of power to the valve.

1. Check, at the valve connector, for the proper voltages during the OPEN and CLOSE commands to the
valve. Replace faulty wiring or driver module (405-0113) if necessary.
2. Verify the servo control valve is responding, fix faulty wiring or replace actuator if the problem is diagnosed
as the valve.
Err
Incorrect switch sequence is selected on the console.
1. Consult Operator’s Manual for correct switch sequence.
Err E
Memory error.
This is often the result of a poor battery connection.

1. Hold down the decrease switch until the alarm stops. Check to see which constants have been set to zero
and re-enter the correct values.
OFLO
Valve to be displayed exceeds the maximum allowable size.
1. Hold down the decrease switch until the display re-sets to zero.
Err L
The vehicle electrical system voltage has fallen below about 10.0 VDC.
1. Establish good ground and battery connections. This is the most common fault when system is acting
erratically.
2. Check and service or replace the vehicle battery.
3. Check and service or replace the vehicle alternator/voltage regulator.
Err C, n hook (backward 7)

Internal diagnostics.
1. May appear from time to time. A momentary appearance, followed by no other problems can be safely
ignored. If occurs frequently, or stays on, contact your MID-TECH dealer.
TEST INSTRUCTIONS AND SOFTWARE RESET

NOTE: Performing the following test sequence also reprograms the ARC for the default constants established
for the software installed in the console. A list of normal default constants is included later in this
manual. Be sure and write down any special constants specific to your installation, e.g. the distance
calibration, before you perform the self test and reset procedure.
1. Turn power OFF. Disconnect all cables from the back of the console, except the power cable.
2. Select TEST SPEED and SET-UP.
3. Turn power ON holding INCREASE switch. (If the console will not power down; select the OPERATE mode,
turn the power OFF, let the unit power down, select SET-UP and power up the console while holding the
INCREASE switch.)
4. RAM TEST The console will display PASS or FAIL and beep.
ARC automatically moves into the display test mode.

8000- 26
5. DISPLAY TEST Count down from 999 to 000 will continue until the DECREASE switch is pressed.
For ARC consoles, proceed to step 6 below.
For TASC consoles, the display will now show SET 1. Move the DISPLAY SELECTOR away from the TEST
SPEED position and the test will then advance to step 6 below.
6. EEPROM TEST The console will display PASS or ERR#.
ERR# means failure of the EEPROM test.
Unit cycles automatically into the segment test.
7. SEGMENT TEST Occurs after the EEPROM test.
Allow unit to sequence until the digits for the switch test are displayed.
NOTE: If you are not concerned about a possible console Switch failure, go directly to step 11.
8. Observe console readings while operating the following switches. First make sure all pump switches are
OFF.
415 OPERATE
405 SET-UP
9. Display the rotary switch starting at the TEST SPEED position. (The following switch position titles apply to
the ARC 6000, TASC 6100, 6300& 6600 unless other wise noted)
405 TEST SPEED
400 SPEED
404 TOTAL AREA (FAN RPM-T6100), (CHEMICALS/Chem. Applied-T6300, 6600)
402% RATE
406 TOTAL APPLIED (CARRIER/Total Applied-T 6300, 6600)
401 DISTANCE
40d SCAN
408 FIELD AREA (AREA-T6100, 6300,6600)
40C PRODUCT VOL. (CHEMICALS/Chem. Rate-T633,6600)
40A APPLICATION RATE (CARRIER/Appl. Rate-T6300, 6600)
40E IMPL. WIDTH
409 PRIME (PSI/Prime-T6100)
10. INPUT TEST Hold the DECREASE switch about three (3) seconds.
The display should read HLLLL or LLLLL (either is acceptable).
11. OUTPUT TEST Press DECREASE switch about three (3) seconds.
The display should read -----. (The console should beep during this test sequence.)
12. ESCAPE THE TEST MODE Turn the console power OFF and back ON to escape the test mode; or, hold
the INCREASE switch for three (3) seconds to reset the start-up routine.
The console has been reprogrammed for the default constants for the software installed, be sure and
reprogram the console with the appropriate constants as required.
US, Metric and Metrish

After performing the software test and reset procedure, use the following procedure to test and set the
appropriate display units for your operation.
Set display selector to PRIME.

Set mode selector to SET-UP.
Use INC switch to select Pump L Stnd Mode (This does not apply to TASC 6300/6600 consoles).
1. Set the display selector switch to SPEED, observe the units to be in the US setting.
2. Select the OPERATE mode.
3. Press the DECREASE switch for about five (5) seconds to select METRIC mode.

8000 - 27
4. Press the DECREASE switch foe another five (5) seconds and the display will go back to the US unit
display.
5. Press the INCREASE switch for about three (3) seconds to enter the METRISH unit readout (ARC only).
DECREASE for five (5) seconds resets to US.
HOLD/CLOSE Of The Flow Control Valve

1. RESPONSE TO THE STATUS SWITCH Boom and pump switches are OFF.
Select power ON and OPERATE.
Set the display selector to TOTAL APPLIED.
Selected response will be indicated by holding the INCREASE switch up until it displays either HoLD or
CLOSE.
Continuing to hold the INCREASE switch will cause the display to cycle between the two (2) responses.
The response displayed when the INCREASE switch is the response set when all boom switches are
turned OFF.
NOTE: SPX units must be set to CLOSE.
2. RESPONSE TO ALL BOOMS OFF Boom and pump switches are OFF.
Select power ON and OPERATE.
Set the display selector to IMPL. WIDTH.
Selected response will be indicated by holding the INCREASE switch up until it displays either HoLD or
CLOSE.
Continuing to hold the INCREASE switch will cause the display to cycle between the two (2) responses.
The response displayed when the INCREASE switch is the response set when all boom switches are
turned OFF.
NOTE: SPX units must be set to HOLD.
Manual Override - ARC 6000/TASC 6100

1. With the console power ON, select OPERATE and place the display selector on APPLICATION RATE.
2. Use the DECREASE switch to set the display to zero (0.0).
3. Hold the DECREASE switch down for about another five (5) seconds, until the display indicates “Flow
CONTI OFF Auto”.
4. Use the INC/DEC switch to open and close the flow control valve.
5. Switch the console power OFF and back ON to clear manual valve override.
6. Remember to re-enter the appropriate APPLICATION RATE.
Manual Override - TASC 6300/6600

1. With the console power ON, select SET-UP and place display selector on CARRIER, APPL. RATE.
All pump control channel switches should be OFF.
2. Use the DECREASE switch to set the application rate displayed to zero (0.0).
3. Select OPERATE mode.
The display will indicate “Flow CONTI OFF Auto”.
4. You can now use the INCREASE/DECREASE switch to operate the flow control valve manually.
5. Re-enter the application rate to clear the manual override mode.

8000- 28
Sprayer Prime Option
1. Start with the console ON, mode selector to OPERATE.
2. Select PRIME, a series of five (5) dashes (-----) will be displayed.
3. Hold the INCREASE switch up for three (3) to five (5) seconds.
The display should read OPEn.
If the AUTORANGE® Valve is connected and powered, it will open fully.
4. Hold the DECREASE switch down for three (3) to five (5) seconds.
The valve will close and the series of five (5) dashes (-----) will be displayed.

8000 - 29
ARC 6000 CONSOLE DEFAULTS

8000- 30
TASC 6100 CONSOLE DEFAULTS

8000 - 31
TASC 6300/6600 CONSOLE DEFAULTS

8000- 32
CONSOLE PIN OUTS AND NORMAL VOLTAGES

(Referenced To Battery Negative Ground)
CONSOLE POWER
PIN COLOR STATUS
1 Black GND
2 Red +12 VDC
GROUND SPEED
PIN COLOR STATUS
1 Black GND
2 White +5 VDC
3 Red +12 VDC
4 Green Jumped to 3 (not used)
FLOW CONTROL

8000 - 33
SERIAL I/O
PIN COLOR STATUS
1 Blue GND (master to auxiliary)

2 Orange +5V (print request)
3 White GND (master to print)
4 Purple 0V (auxiliary to master)
5 Green +5V (print busy)
6 Black GND
7 Red +12V (filtered, switched)
8 Brown +5V (transmit enable)
9 Yellow +12V (switched)
BOOM INTERFACE
PIN COLOR STATUS
1 Black GND
2 Red +12VDC
3 Green in select
4 Blue data out
5 Orange shift in
6 White out select
7 Yellow clock
8 Brown flash VOLTS in
NOTE: Pins 3 through 8 require special equipment to check

8000- 34
PROCEDURE TO VERIFY SIGNALS FROM THE RAVEN FLOW METER

NOTE: Please see the System Diagram in the appendix for location of components.
Procedure To Test The Flow Meter Sensor Output To The ARC Console.
This procedure works best with two people, one to perform the actions required and one to observe the
reaction of the control console.
Perform this test without the engine running. You do not need actual pump output from the main
product pump.
1. Put the main valve in manual override, “Flow Contl OFF Auto”
2. Make sure there is at least some speed entered in the GSO (SPEED and SET-UP) position and turn ON
the GSO switch (if equipped).
3. Set the flow meter calibration number to 1.0. Put the display selector to the TOTAL APPLIED position.
4. Turn ON the boom master switch (make sure at least one of the boom indicators is lit on the console face).
5. Unplug the flow meter adapter cable (Case Tyler Supplied) from the flow meter.
6. Using a knife blade, screwdriver, nail, etc., carefully short across pins 1 and 2 on the adapter cable
connector. You should observe one count accumulation on the console display every time you make and
break the contact on pins 1 and 2.
NOTE: BE CAREFUL: Shorting the power connection (Pin 3) to either Pin 1 or Pin 2 will blow a fuse and
possibly damage the control console.
2 - Signal
1 - Ground 3 - +5V
• If counts accumulate normally, the problem is associated with the flow meter.
• If counts do not accumulate normally, follow the adapter cable back toward the console until you find the
three pin Weatherpack connector in the frame harness. Disconnect the adapter cable from the main har-
ness. Using a VOLT/OHM METER, test the pins on the frame harness connection.
Pin A should be +5 VDC (tested to frame ground)

Pin B should be Ground
Pin C should be >+05 VDC (tested to frame ground)
• If these voltages are present, the problem must be in the frame harness.
• If these voltages are not correct, disconnect the 405-0156 from the back of the console, and check for the
correct voltages on Pins 2, 3 & 5 of the Flow Control connector (Control Channel-C for the TASC 6100), as
shown in the table (See page 8000-32 of this manual).
• If the voltages at the back of the console are correct, the 405-0156 is defective.
• If the voltages are not correct the console is defective.
• If all voltage checks are correct, and shorting between the signal line and ground at all connections does
not result in the console counting gallons, the console is defective and should be returned to MID-TECH for
repairs.
NOTE: The 405-0156 flow control cable contains a voltage regulator that converts the +12V flowmeter power
line (Pin 2 on the console flow control connector) to +5V at Pin A where 405-0156 connects to the
frame harness.
8000 - 35
Verifying The Acre Count
If you suspect the acre accumulator is not working correctly, it is easy to verify its accuracy.
You will need an accurately measured mile, for example a straight road between two sections.
1. First, zero the distance accumulator and drive the distance to check the accuracy of the speed sensor.
If you are not reading within 50 feet in a mile, calibrate the speed sensor.
NOTE: Do not rely on your vehicles’ odometer as inaccuracies of up to ten percent are typical.
2. Next, calculate the area covered in one mile by your vehicle when applying at the full swath width.
Use the formula: AREA = (5280 feet X SWATH WIDTH in feet) / 43560 FT2
3. Drive to the start of the measured mile.
Set the area accumulators to zero using the DECREASE switch.
4. Put the valve in manual override (See Page 8000-27).
5. Turn the booms ON (since you will not actually be discharging product you can leave them folded in), and
drive to the other end of the measured mile.
6. Turn the booms OFF and check the area accumulator.
You should be reading within one percent of the calculated area.
EXAMPLE: A vehicle with a 60 foot swath width will cover 7.27 acres in a distance of one measured mile (5280
feet). An area accumulator reading between 7.20 and 7.34 would represent an area accumulator
accuracy of one percent or better.
Verifying The Operation Of MID-TECH Control Valves

The following procedure works best with two people, one to perform the actions required at the console, the
other to observe the valve response or voltages.
Perform this test without the engine running. You do not need actual pump output from the main
product pump.

8000- 36
Verifying The Operation Of MID-TECH Control Valves (Cont’d)
1. Put the valve into manual override. “Flow Contl OFF Auto”.
• Hold INC switch UP and observe the valve stem rotates OPEN.
• Hold DEC switch DOWN and observe the valve stem rotates CLOSED.
• Full open to full closed is about a 90° rotation of the valve stem for a MID-TECH valve (about 3
seconds).
If the valve responds properly, all is OK. Look somewhere else for the source of the problem.
If the valve does not respond normally, go to Step 2.
2. Check for proper power at the valve.

Disconnect the four pin PACKARD connector between the valve driver (405-0113) and the valve.
With a Volt/Ohm Meter (VOM), you will test between pins A, B, and C.
• Hold INC switch UP, observe voltage rising to +12 VDC at pin B, measured to pin C.
• Hold DEC switch DOWN, observe voltage rising to +12 VDC at pin C, measured to pin B.
• Pin A should be a continuous +12 VDC, measured to vehicle frame ground.
If power checks OK, problem is in the valve. Remove and replace.
If power does not check, go to Step 3.
3. Check for proper power at the six pin PACKARD connector between the frame harness and the valve
driver.
With a Volt/Ohm Meter (VOM), test pins A, B, C. and D on the flow control cable, six pin connector.
• Hold the INC switch UP, measure voltage rising to +12 VDC at pin C, measured to pin D.
• Hold DEC switch DOWN, measure voltage rising to +12 VDC at pin D, measured to pin C.
• Pin A should be a continuous +12 VDC, measured to ground on pin B.
If power checks OK, problem is in the valve driver. Remove and replace.
If power does not check, go to Step 4.
4. Repeat step 3 (first two steps only) where the 405-0156 cable meets the frame harness in the electrical
side panel.
5. Check for proper output from the control console.
Disconnect the 405-1056 from the back of the console.
With a Volt/Ohm Meter (VOM), test pins 1 and 4.
Hold the INC switch UP, measure voltage rising to +12 VDC at pin 1, measured to pin 4.
Hold DEC switch DOWN, measure voltage rising to +12 VDC at pin 4, measured to pin 1.
NOTE: BE CAREFUL: Not to short between the pins as damage to the console may occur.
If power checks OK, the fault is in the flow control cable. Remove and repair or replace.
If power does not check, the fault is in the console. Remove and repair or replace.

8000 - 37
SPX / MID-TECH WIRING DIAGRAM

Case IH Supplied Speed Sensor And Valve
(Case IH supplied)
(Case IH supplied valve)

8000- 38
SPX / MID-TECH WIRING DIAGRAM

Case IH Supplied Speed Sensor
(CASE IH SUPPLIED)
1 1/2” Auto Range Valve

879-0072

NOT ALL LINES SHOWN
AUTO-RANGE® CONTEROL VALVE

REGULATED LINE
IN-LINE FILTER
SUPPLY TANK
TO BOOMS
SPARGE CONTROL VALVE

FLOW METER
BY-PASS LINE
SUPPLY LINE BOOM VALVES
CARRIER PUMP
AUTO-RANGE® SYSTEM PLUMBING DIAGRAM
QUICK FILL SPARGE LINE
Controller Systems
8000 - 39
8000- 40
NOT ALL LINES SHOWN

REGULATED LINE

SUPPLY TANK
IN-LINE FILTER
TO BOOMS
SPARGE CONTROL VALVE
FLOW METER
BY-PASS LINE
CARRIER PUMP SPARGE LINE

SUPPLY LINE BOOM VALVES
QUICK FILL
BY-PASS CONTROL VALVE

BY-PASS VALVE SYSTEM PLUMBING DIAGRAM
Controller Systems
A A BLK (+12)
B B GRN (MA) *OPEN*
A RED (+12) A C C WHT (MB) *CLOSE*
D D RED (E2)
B BLK (GND) B

C GRN (OPEN)

C
D WHT (CLOSE) D
E BRN (E1) E
F NONE F
ER
D RIV
VE
VAL
401-0027/405-0113
REVERSE VALVE DRIVER CABLE
Controller Systems
8000 - 41
8000- 42

RED
IMP STAT BLK
PINS SKTS
A A RED A
BOOM STATUS GSO
B B BLK B
78-05015
DATA OUT
PINS
BOOM STATUS A BRN
A
B B RED
405-0156/78-0501
C C ORN
D D YEL
E E GRN
F F BLU
9 BOOM INTERFACE WITH IS/GSO
A A PUR
B B BLK
C C WHT
D D PLUG
Controller Systems
8000 - 43
AUTO-RANGE® VALVE

8000- 44
Parts Identification
1 1/2” Auto-Range Valve
879-0072
5
6
7
8 2
9 2
3
3
4
1. Actuator Motor and Electronics - 879-0104

2. Polypropylene Valve Body
3. Ball Seal
4. Valve Body O-Ring Seal
5. Snap Ring
6. Stem Spacer
7. Stem O-Ring Seal
8. Teflon Stem Washer
9. Valve Ball
NOTE: The following numbers are included in the repair kit (879-1072) 3, 4, 5, 6, 7, 8,and 9

8000 - 45
SERVICE SHEET
Values Displayed By ARC-6000
Fill Out Before Calling For Faster Service
SOFTWARE VERSION:______________________
Number displayed when console first powers up; e.g. 1.31
MODE SWITCH SETTING OPERATE SET-UP
FIELD AREA______________
TOTAL AREA______________
PRODUCT VOL.___________
% RATE__________________
APPLICATION RATE _______
TOTAL APPLIED___________
IMPL. WIDTH______________
DISTANCE________________
PRIME ___________________
TEST SPEED _____________
SCAN ____________________
SPEED___________________
ERROR MESSAGE DISPLAYED?

C___________________
_______________________________________________________
1___________________
2___________________
_______________________________________________________
BOOM WIDTHS
3___________________
OTHER INFORMATION? 4___________________
5___________________
_______________________________________________________
6___________________
7___________________
_______________________________________________________
8___________________
_______________________________________________________ 9___________________

Section No. - 46

9000
Section 9000
SPX 4260 REQUIRED AND RECOMMENDED
TOOL LIST

260 Highway 12 SE
© 2003 Case, LLC

Issued 2-03 Printed in U.S.A. SPX 4260 Required And Recommended Tool List
9000 - 3
SPX 4260 Required And Recommended Tool List

General Information
1. The following are the required and recommended tool lists for predelivery inspection and service of the
Case IH Application Equipment sprayer products.
2. Following is a list of the required and recommended tools and their suppliers.
3. Some of these tools are available from different suppliers.
4. Pricing has been omitted as dealers may choose to source the tooling through their own suppliers.
5. No effort has been made to currently price the tools as prices are subject to change for many reasons.
6. OTC has distributed all required tooling in the past.
7. Case IH Ag Equipment distributes most of the chemicals in the required tooling list.
8. The listing of manufactures is intended only as a guide to either a known manufacture has been supplied.
9. To obtain copies of the tool manufacture’s catalogues the mailing address of each manufacture has been
supplied.
10. These catalogues can most likely be sourced quickly and locally from tool distributors in the CIHAE
Dealer’s immediate area.
11. Attached are the bulletins describing the tool kits supplied for CNH/CIHAE by OTC in the past.
12. Please contact your technical support representative with any questions.
NOTE: It is recommended only quality service tooling and product is acquired and used in the service of SPX
product.
List Of Acronyms And Tool Supplier Addresses
CNH OTC
CNH Benson Owatana Tool Company
Case IH Application Equipment 655 Eisenhower Drive
260 Highway 12 SE Owatana, Minnesota
Benson, Minnesota 56215 55060-9911
CRC Sauer
CRC Canada Inc. Sauer-Danfoss
1246 Lorimar Drive 2800 East 13th Street
Unit # 2, Mississauga, Ontario Aimes, Iowa
L5S 1R2 50010 USA
SNAP-ON MAC TOOLS

2801 - 80th Street Mac Tools Corpration
Snap-On Tools Company 4635 Hilton Corp. Drive
Kenosha, Wisconsin Columbus, Ohio
53141 - 1410 43232

9000 - 4
SPX 4260 Required And Recommended Tool List

Required Tools
Chemicals - Cleaners, Sealants and Lubricants:
Tool # Description Supplier Quantity
J822934 Dielectric Grease-Low Voltage Electrical/Elec- CNH 1 Case

tronic Connections
345-92 Dielectric Grease-Low Voltage Electrical/Elec- CNH 1 Case

tronic Connections
B505516 Dielectric Tune Up Grease For Spark Ignition CNH 1 Case

and Other High Voltage Wires
B505514 Battery Connection Cleaner CNH 1 Case
B505515 Battery Connection Saver Lubricant CNH 1 Case
B505513 Electrical Cleaner CNH 1 Case
75012 Quick Dry Electrical Contact CL. CRC 1 Case
ZRG017BRC Brake & Parts Cleaner CNH 1 Case
ZRG012WGC Lithium White Grease CNH 1 Case
B505503 Heavy Duty Silicone Lubricant CNH 1 Case
B17425 Thread Sealant With Teflon CNH 1 Case
B17427 Plastic Gasket CNH 1 Case
B17424 # 290 WICKNLOCK CNH 1 Case
B17578 # 242 LOCKNSEAL CNH 1 Case
B17271 # 271 THREADLOCK CNH 1 Case
B17580 # 262 THREADLOCK CNH 1 Case
B17426 # HYDRAULIC SEALANT CNH 1 Case
B17507 # ANTI SEIZE COMPOUND CNH 1 Case
B17555 # 515 GASKET ELIMINATOR CNH 1 Case
# 542 Hydraulic Sealant 1 Case
B504266 Weather Strip Adhesive CNH 1 Case
B17575 General Purpose RTV Silicone CNH 1 Case
B504324 High Performance RTV Silicone CNH 1 Case

9000 - 5
SPX 4260 Required And Recommended Tool List (Cont’d)

Required Tools (Cont’d)
Park Brake Release Tool Kit (325022)

SPX 4260-778C
Tool # Description Supplier Quanity
BN 310312 Multi-Function Valve By-Pass Wrench CNH 1
BN 310313 Multi-Function Valve By-Pass Wrench CNH 1
BN 324972 Hand Pump Assembly CNH 1
BN 322836 Instructions CNH 1
SPX 4260 Tool Kit (TY 1000A)

Suspension and Chassis
Bulletin No. CT 99-1
TY 1001 Suspension Bushing Installer OTC 1
TY 1002 Suspension Pin Remover OTC 1
TY 1003 Steering Bushing Installer OTC 1
Suspension and Chassis

TY 1004 Fairfield Hub Spanner Wrench OTC 1
TY 1006 Spindle Torque Wrench Adapter OTC 1
Motor Flush Defeat Spools (90 Series)

Sauer Sunstrand (Sauer Danfoss)
BN 321231 Spool CNH 1
BN 321232 Plug / Cap CNH 1
Multi-Function Valve By-Pass Wrench

(Towing)
310312 Multi-Function Valve By-Pass Wrench CNH 1
310313 Multi-Function Valve By-Pass Wrench CNH 1

9000 - 6

Recommended Tools
Cooling System Service

NOTE: It is recommended good quality gauges be purchased and used.
OEM 1347 Cooling System Pressure Tester (20 PSI Max.) OTC 1
OEM 1041 Cooling System Pressure Tester (30 PSI Max.) OTC 1
OEM 1348 Truck Adapter Kit OTC 1
OEM 1349 Threaded Adapter OTC 1
OEM 1044 Anti-Freeze Tester OTC 1
Heat Detection
RTEMP6PB Infra Red Heat Gun SNAP-ON 1
Electrical / Electronic Diagnostics Equipment

(Electrical Service)
MT 3760 AVR Tester SNAP-ON 1
MT 302A Remote Start Switch SNAP-ON 1
BC 20500 Booster Cables SNAP-ON 1 Set
OEM 1053 Battery Loader Tester OTC 1
Terminal Connector Kit and Service Tools
ZJL140004 Terminal Service Kit CNH 1 Kit
TT 600 Terminal Tool Kit SNAP-ON 1
GA 500A Wire Terminal Tool SNAP-ON 1
YA 500GM Wire Terminal Tool SNAP-ON 1
Digital Multi-Meters
FLUKE 88 Digital Muti- Meter FLUKE MFG. 2
ET 1000 DC Amp Induction Meter MAC TOOLS 1
Speed Simulators
456404511S1 Speed Simulator DICKEY-john 1
Circuit Test Tools
YA7707 Gauge Tester SNAP-ON 1
THX187 Amp Amplifier SNAP-ON 1
FZ8A Fuse Tester Remover SNAP-ON 1
FZ4A Fuse Tongs SNAP-ON 1
YA8616 Fuse Tap SNAP-ON 1

9000 - 7

Recommended Tools (Cont’d)
Electrical / Electronic Diagnostics Equipment

(Circuit Test Tools)
YA9010 Bosch Relay Pliers SNAP-ON 1
THX441 Fuse Block Test Adapter Kit SNAP-ON 1
OEM 7744 Anti Static Wrist Wrap OTC 1
Test Lead Kits
TLS7 Test Leads SNAP-ON 2
Test Lead Kit SX Controller Calibration Break Out Harness SHOP 2

FABRICATE
Test Lead Kit PCP Break Out Harness SHOP 2

FABRICATE
Test Lead Kit Bosch STD Relay Break Out Harness SHOP 2
FABRICATE
Test Lead Kit Bosch Mini Relay Break Out Harness SHOP 2
FABRICATE
Test Lead Kit Fuse Break Out Harness SHOP 2

FABRICATE
Fuel System Service

NOTE: It is recommended quality liquid filled gauges be purchased and used.
J-38641 Fuel Hydrometer KENT MOORE 1
OEM 1447 30 In. Hg / 30 PSI OTC 4
OEM 1452 30 In. Hg / 150 PSI OTC 1
Hydraulic Service Tools

Suspension Bushing Installers
OEM 6019 Air / Hydraulic Pump OTC 1
OEM 6021 Hydraulic Hand Pump OTC 1
OEM 6025 30 Ton Twin Cylinder Ram OTC 1
OEM 9780 72 In. X 3/8 In. ID, NPTF Fittings OTC 1

(10,000 PSI Operating Pressure, 20,000 PSI
Burst Pressure)

9000 - 8

Hydraulic Diagnostic Equipment

(Hydraulic Flow Meter)
OEM 1249 5 GPM Flow Meter OTC 4
OEM 1239 75 GPM Flow Meter OTC 1
Electronic Pressure Gauge Kit
OEM 1653 Kit OTC 1
OEM 1661 Gauge Protector OTC 4
OEM 1604 10,000 PSI Pressure Transducer OTC 2
OEM 1607 20 Ft. Cable OTC 4
OEM 1606 12 Ft. Cable OTC 4
OEM 1602 500 PSI Pressure Transducer OTC 2
Hydraulic O-Ring Kits
B91398 O-Ring Face Seal Kit CNH 1
407060R91 Standard O-Ring Kit CNH 1
Gauge Protectors
OEM 1213 Snubbers OTC 6
Test Hoses And Drain Pans

NOTE: All test hoses must have a working pressure rating in excess of the system pressure being tested.
No. 4 Hose 25 Ft. SHOP 4

FABRICATE
Hydraulic Drain Pan (48 In. X 48 In. X 6 In.) 1

9000 - 9

Hydraulic Diagnostic Equipment

(Pressure Gauges)
NOTE: It is recommended quality liquid filled gauges be purchased and used.
* Denotes a liquid filled gauge. Gauge must capable of measuring maximum system pressure.
OEM 1447 30 In. Hg / 30 PSI OTC 4
OEM 1447 30 In. Hg / 150 PSI OTC 4
OEM 1451 100 PSI OTC 4
OEM 1209* 600 PSI OTC
OEM 1460 1,000 PSI OTC 4
OEM 1462 3,000 PSI OTC 4
OEM 1210* 5,000 PSI OTC 4
OEM 1464 6,000 PSI OTC
OEM 1465 10,000 PSI OTC 4
Hydraulic Tank Vacuum Adapter (CNH)

* With 0 - 600 PSI Pressure Gauge
BN 322481 With Out 5 PSI Check Valve CNH 1
BN 323678 With 5 PSI Check Valve CNH 1
BN 311682* Single Stage Pump CNH 1
OEM 6454 Single Stage Pump OTC 1
Fluid Leak Detection
OEM 1639 UV Florescent Leak Detection Master Kit OTC 1
OEM 1624 Diesel Engine Oil Tracer OTC 1
OEM 1630 Fuel System Tracer Dye OTC 1
OEM 1628 Hydraulic Oil Tracer Dye OTC 1
OEM 1638 R - 134A / PAG Tracer Dye OTC 1
OEM 1650 R - 134A / Ester Tracer Dye OTC 1
OEM 1634 A / C System Dye Injector OTC 1

9000 - 10

Hydraulic Fittings And Adapters

IMPORTANT: All hydraulic fittings and hoses / lines must be capable of withstanding the system pressures
being tested.
NOTE: No suppliers of hydraulic fittings have been listed. OTC, Acklands-Grainger and Hydratec Hydraulics are
sources in addition to the fittings available through both the Case IH Ag and CE Divisions. Some adapters may
need to be fabricated using fittings and hose.
NPTF to JIC Adapters
No. 4 NPTF to JIC Adapter 4
NPTF to ORB Adapters
No. 4 NPTF to ORB Adapter 4
NPTF to Flat Face O-Ring Seal Adapters
No. 4 NPTF to Flat Face O-Ring Seal Adapter 4

9000 - 11


being tested.
JIC to ORB Adapters
No. 4 JIC to ORB Adapter 4
JIC to Flat Face O-Ring Seal Adapters
No. 4 JIC to Flat Face O-Ring Seal Adapter 4
JIC Tee’s
No. 4 JIC Tee 4
No. 6 JIC Tee 4
No. 8 JIC Tee 4
No. 10 JIC Tee 4
No. 12 JIC Tee 4
No. 16 JIC Tee 4

9000 - 12


being tested.
ORB Tee’s
No. 4 ORB Tee 4
No. 6 ORB Tee 4
No. 8 ORB Tee 4
No. 10 ORB Tee 4
No. 12 ORB Tee 4
No. 16 ORB Tee 4
Flat Face O-Ring Seal Tee’s
No. 4 Flat Face O-Ring Seal Tee 4
JIC Plugs
No. 4 JIC Plug 4
No. 6 JIC Plug 4
No. 8 JIC Plug 4
No. 10 JIC Plug 4
No. 12 JIC Plug 4
No. 16 JIC Plug 4

9000 - 13


being tested.
ORB Plugs
No. 4 ORB Plug 4
No. 6 ORB Plug 4
No. 8 ORB Plug 4
No. 10 ORB Plug 4
No. 12 ORB Plug 4
No. 16 ORB Plug 4
Flat Face O-Ring Seal Plug’s
No. 4 Flat Face O-Ring Seal Plug 4
JIC Caps
No. 4 JIC Caps 4
No. 6 JIC Caps 4
No. 8 JIC Caps 4
No. 10 JIC Caps 4
No. 12 JIC Caps 4
No. 16 JIC Caps 4

9000 - 14


being tested.
ORB Caps
No. 4 ORB Caps 4
No. 6 ORB Caps 4
No. 8 ORB Caps 4
No. 10 ORB Caps 4
No. 12 ORB Caps 4
No. 16 ORB Caps 4
Flat Face O-Ring Seal Caps
No. 4 Flat Face O-Ring Seal Cap 4
No.16 Flat Face O-Ring Seal Cap 4
General Tools
Torque Wrenches and Torque Multiplier

NOTE: It is recommended quality torque wrenches be purchased and used. All torque wrenches must have
their calibration verified as required.
Torque Wrench 3/8 In. Drive Rotary Dial IN / LB SNAP-ON 1
Torque Wrench 3/8 In. Drive FT/ LB SNAP-ON 1
4 X Multiplier 1/2 In. to 3/4 In. Drive SNAP-ON 1

9000 - 15

General Tools (Cont’d)
Hydraulic Jacks and Stands

NOTE: All lifting and supporting devises must have a weight rating in excess of the loads lifted and/or
supported.
OEM 1656 12 Ton Jack OTC 2
Jack Stands Must Be Capable Of Supporting a Fully SHOP 4

Loaded Unit. FABRICATED


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SPX Series

! CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE

● DANGER: Indicates an immediate hazardous situation that, if not avoided, will

● WARNING: Indicates a potentially hazardous situation that, if not avoided,

● CAUTION: Indicates an potentially hazardous situation that, if not avoided,

● The first panel indicates the nature of the hazard.

● Is instructed in safe and proper use of the machine.

● Reads and understands the Manual(s) pertaining to the machine.

● Reads and understands ALL Safety Decals on the machine.

● Clears the area of other persons.

© 2003 Case, LLC 86986705

CASE and IH are registered trade marks of Case, LLC

Manuals are available from your Dealer for the operation,

Your Dealer can expedite your order for operator’s manuals,

Always give the Machine Name, Model and P.I.N. (product

Diesel engine exhaust and some of its

Battery posts, terminals and related accessories

NOTE: CNH America LLC reserves the right to make improvements in

STANDARD TORQUE SPECIFICATIONS AND LOCTITE PRODUCT CHART . . . . . . . 1000

GENERAL INFORMATION AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002

MINOR ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4000

STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4001

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5000

SPRAY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6000

A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7000

CONTROLLER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8000

SPX 4260 REQUIRED AND RECOMMENDED TOOL LIST . . . . . . . . . . . . . . . . . . . . . . 9000

CASE IH APPLICATION EQUIPMENT

© 2003 Case, LLC

SPX 4260 Troubleshooting Manual

STANDARD TORQUE SPECIFICATIONS

LOCTITE PRODUCT CHART

Case IH Application Equipment

© 2003 Case, LLC

SPX 4260 Troubleshooting Manual

TORQUE SPECIFICATIONS - DECIMAL HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

TORQUE SPECIFICATIONS - METRIC HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . .6

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS . . . . . . . . . . . . . . . . . . . . . .7

SPX 4260 Troubleshooting Manual

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Size Pound-Inches Newton Metres Size Pound-Inches Newton Metres

Size Pound-Feet Newton Metres Size Pound-Feet Newton Metres

SPX 4260 Troubleshooting Manual

TORQUE SPECIFICATIONS - METRIC HARDWARE

Size Pound-Inches Newton Metres Size Pound-Inches Newton

Grade 12.9 Bolts, Nuts and Studs

SPX 4260 Troubleshooting Manual

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

37 Degree Flare Fitting Straight Threads with O-Ring

1/4 inch 7/16-20 72 to 144 8 to 16 1/4 inch 7/16-20 144 to 228 16 to 26

Split Flange Mounting Bolts

5/16-18 180 to 240 20 to 27

Size Pounds-Inches Newton Metres

SPX 4260 Troubleshooting Manual

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

-4 1/4 inch 9/16-18 120 to 144 14 to 16 7/16-20 204 to 240 23 to 27

SPX 4260 Troubleshooting Manual