New Holland Workmaster 50 Page 146 Service Manual Download

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Transmission - Mechanical transmission

Mechanical transmission - Troubleshooting

Problem

Possible Cause

Correction

Noisy operation with
range in neutral and main
lever engaged

Input and output shaft support bearing mis-
adjusted.

Remove transmission housing and adjust
bearings.

Failed or defective inner component.

Remove housing, overhaul transmission
and replace faulty parts.

Internal component seizure due to poor lu-
brication.

Overhaul transmission and top up oil to cor-
rect level.

Noisy operation with
tractor stationery, idling
engine and transmission
in neutral

Faulty clutch plate springs.

Replace clutch plates.

Self disengagement of
speed, range gears

External linkage and levers mis-adjusted.

Adjust correctly.

Failed control rail retaining springs.

Replace springs.

Partial engagement travel.

Correct reasons for problem and restore full
travel.

Difficult engagement of
speed and range gears

External levers mis-adjusted.

Adjust correctly.

External levers stiff or seized.

Check pivot points and correct.

Internal control items (rails, forks and
sleeves) slide with difficulty.

Overhaul control items.

47866583_ 02/12/2015

21.1 [21.114] / 29

Summary of Contents for Workmaster 50

Page 1: ...r 50 Workmaster 60 Workmaster 70 Tier 4B final Tractor Printed in U S A 2015 CNH Industrial America LLC All Rights Reserved New Holland is a trademark registered in the United States and many other countries owned by or licensed to CNH Industrial N V its subsidiaries or affiliates ...

Page 2: ...SERVICE MANUAL Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 EN ...

Page 3: ...HP TIER 4B FINAL North America R 753 IE4 Workmaster 60 Compact tractor 2WD 60 HP TIER4B FINAL North America R 753 IE4 Workmaster 60 Compact tractor 4WD 60 HP TIER 4B FINAL North America R 753 IE4 Workmaster 70 Compact tractor 2WD TIER 4B FINAL North America R 753 IE4 Workmaster 70 Compact tractor 4WD 70 HP TIER 4B FINAL North America R 753 IE4 47866583_ 02 12 2015 ...

Page 4: ...nts 18 2 Transmission 21 21 114 Mechanical transmission 21 1 21 130 Mechanical transmission external controls 21 2 21 140 Mechanical transmission internal components 21 3 21 145 Gearbox internal components 21 4 21 200 Dropbox 21 5 Four Wheel Drive 4WD system 23 23 314 Drive shaft 23 1 Front axle system 25 25 100 Powered front axle 25 1 25 102 Front bevel gear set and differential 25 2 25 108 Final...

Page 5: ... service brakes 33 1 Hydraulic systems 35 35 000 Hydraulic systems 35 1 35 100 Main lift system 35 2 35 104 Fixed displacement pump 35 3 35 204 Remote control valves 35 4 35 300 Reservoir cooler and filters 35 5 35 355 Hydraulic hand control 35 6 35 359 Main control valve 35 7 Steering 41 41 101 Steering control 41 1 41 200 Hydraulic control components 41 2 41 206 Pump 41 3 41 216 Cylinders 41 4 W...

Page 6: ...ttery 55 7 55 404 External lighting 55 8 55 405 External lighting switches and relays 55 9 55 408 Warning indicators alarms and instruments 55 10 55 512 Cab controls 55 11 55 DTC FAULT CODES 55 12 Platform cab bodywork and decals 90 90 100 Engine hood and panels 90 1 90 110 Operator platform less cab 90 2 90 116 Fenders and guards 90 3 90 118 Protections and footboards 90 4 47866583_ 02 12 2015 ...

Page 7: ...47866583_ 02 12 2015 ...

Page 8: ...INTRODUCTION 47866583_ 02 12 2015 1 ...

Page 9: ...ts INTRODUCTION Foreword 3 Foreword Ecology and the environment 4 Advice 5 International symbols 6 Safety rules 7 Basic instructions hardware 11 General specification Biodiesel Fuels 12 47866583_ 02 12 2015 2 ...

Page 10: ...erly service the model tractors Use this manual in conjunction with the operator s manual for complete operation adjustment and maintenance information On NEW HOLLAND equipment left and right are determined by standing behind the unit looking in the direction of travel 47866583_ 02 12 2015 3 ...

Page 11: ...em contain substances which may be harmful to your health Modern oils contain additives Do not burn contaminated fuels and or waste oils in ordinary heating systems Avoid spillage when draining off used engine coolant mixtures engine gearbox and hydraulic oils brake fluids etc Do not mix drained brake fluids or fuels with lubricants Store them safely until they can be disposed of in a proper way t...

Page 12: ...INTRODUCTION Advice BT09A213 1 47866583_ 02 12 2015 5 ...

Page 13: ...screen wash wipe Ground speed Hitch raise rear Engine oil pressure Rear wind screen wash wipe Differential lock Hitch lower rear Engine coolant temperature Heater temp erature control Rear axle oil tem perature Hitch height limit rear Coolant level Heater fan Transmission oil pressure Hitch height limit front Tractor lights Air conditioner FWD engaged Hitch dis abled Headlamp main beam Air filter ...

Page 14: ...mental safety regulations In most case accidents can be avoided by foreseeing possible causes and consequently acting with the necessary caution and care Accidents may occur with all types of machines regardless of how well the machine in question was designed and built A careful and informed service technician is the best guarantee against accidents Decisive awareness of the most basic safety rul...

Page 15: ...s in the Decal section of this manual Servicing the tractor 1 The cooling system operates under pressure which is controlled by the radiator cap It is dangerous to remove the cap while the system is hot Always turn the cap slowly to the first stop and allow pressure to escape before removing the cap entirely 2 Keep any type of open flame away from the tractor and do not smoke while refuelling Wait...

Page 16: ...e in an enclosed building without adequate ventilation Exhaust fumes can cause death or illness 8 If the power steering or engine ceases operating stop the tractor immediately 9 Pull only from the drawbar or the lower link drawbar in the down position Use only a drawbar pin that locks in place Pulling from the tractor rear axle or any point above the axle may cause the tractor to upset 10 If the f...

Page 17: ...expansion 6 Wipe up spilled fuel immediately 7 Always tighten the fuel tank cap securely 8 If the original fuel tank cap is lost replace it with a NEW HOLLAND approved cap A non approved proprietary cap may not be safe 9 Keep equipment clean and properly maintained 10 Do not drive equipment near open fires 11 Never use fuel for cleaning purposes 12 Arrange fuel purchases so that winter grade fuels...

Page 18: ...ead of tensioning stretching it The tension on the bolt is what holds the joint together Approximately 90 of the torque applied during assembly goes to overcoming friction between the parts The other 10 is used to tension stretch the bolt After assembly the frictional forces disappear which is the basis for the saying If it does not fail during assembly it will not fail in service The bolt may lat...

Page 19: ...may be necessary to change the engine oil engine oil filter and fuel filter elements more frequently than with Diesel Fuels Biodiesel Fuel can remove rust and particles from the inside of on site fuel storage tanks that would normally adhere to the sides of the tank Like particle deposits that commonly occur with Diesel Fuel these particles can become trapped by the machine fuel filters causing bl...

Page 20: ...SERVICE MANUAL Engine Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 10 ...

Page 21: ... Engine and crankcase 10 1 10 103 Crankshaft and flywheel 10 2 10 202 Air cleaners and lines 10 3 10 206 Fuel filters 10 4 10 216 Fuel tanks 10 5 10 310 Aftercooler 10 6 10 400 Engine cooling system 10 7 47866583_ 02 12 2015 10 ...

Page 22: ...Engine 10 Engine and crankcase 001 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 10 1 10 001 1 ...

Page 23: ...Contents Engine 10 Engine and crankcase 001 SERVICE Engine Remove 3 Install 15 47866583_ 02 12 2015 10 1 10 001 2 ...

Page 24: ... in this manual including protective goggles gloves and safety footwear Failure to comply could result in death or serious injury W0208A 1 Remove the front weights 1 GNIL14TR00829AA 1 2 Slide the lock 1 to right hold and raise the hood GNIL14TR00533AA 2 3 Disconnect the battery terminals NOTE Always disconnect the negative cable 1 first GNIL14TR00784AA 3 47866583_ 02 12 2015 10 1 10 001 3 ...

Page 25: ...and nuts 2 from engine frame GNIL14TR00856AA 4 5 Disconnect headlight and horn harness connection 1 6 Unscrew gas strut bolt 2 and remove the front hood GNIL14TR00822AA 5 7 Loosen the bolts 1 and remove the silencer guard GNIL14TR00631AA 6 47866583_ 02 12 2015 10 1 10 001 4 ...

Page 26: ...encer mounting bolts 1 and 2 9 Remove the silencer 3 GNIL14TR00611AA 7 10 Disconnect the electric connection 1 to starter motor GNIL14TR00713AA 8 11 Disconnect the fuel supply and return lines GNIL14TR00712AA 9 47866583_ 02 12 2015 10 1 10 001 5 ...

Page 27: ...14TR00512AA 10 13 Remove the steering wheel securing nut 1 GNIL14TR00846AA 11 14 Remove the steering wheel using tool number 380001672 and 380003008 GNIL14TR00704AA 12 15 Disconnect the wiring 1 on the steering column GNIL14TR00711AA 13 47866583_ 02 12 2015 10 1 10 001 6 ...

Page 28: ... screw 1 and remove the hand throttle knob GNIL14TR00706AA 15 18 Unscrew all the screws securing instrument panel to the rear hood GNIL14TR00707AA 16 19 Pull out the instrument panel from the rear hood 20 Disconnect all the wirings of the instrument cluster GNIL14TR00714AA 17 47866583_ 02 12 2015 10 1 10 001 7 ...

Page 29: ...r hood GNIL14TR00849AA 18 22 Lift and remove the rear hood GNIL14TR00715AA 19 23 Disconnect the diesel overflow pipe 1 on the fuel tank 24 Disconnect the fuel sensor electric connection 2 GNIL14TR00719AA 20 25 Loosen the bolts and remove the bracket that holds the fuel tank strap GNIL14TR00852AA 21 47866583_ 02 12 2015 10 1 10 001 8 ...

Page 30: ...is more than half filled GNIL14TR00709AA 22 27 Loosen the bolts 1 and remove the wiring couplers at the rear of fuel tank GNIL14TR00851AA 23 28 Disconnect the wiring from the adaptor under the rear hood GNIL14TR00855AA 24 29 Remove the bolts 1 30 Remove the adaptor 31 Remove the fuel tank GNIL14TR00727AA 25 47866583_ 02 12 2015 10 1 10 001 9 ...

Page 31: ...AA 26 33 Remove all the bolts securing the fuel tank base plate to the clutch housing 34 Remove the fuel tank base plate GNIL14TR00850AA 27 35 Disconnect the hydraulic line between the pump and the mid mount valve GNIL14TR00783AA 28 36 Loosen the clamp and remove the suction pipe from the hydraulic filter GNIL14TR00725AA 29 47866583_ 02 12 2015 10 1 10 001 10 ...

Page 32: ...filter GNIL14TR00728AA 30 38 Disconnect the power steering hoses on the steering motor GNIL14TR00740AA 31 39 Loosen the bolts 1 of the 4WD shaft cover GNIL14TR00823AA 32 40 Remove the circlip and slide the coupler 1 backward GNIL14TR04359AB 33 47866583_ 02 12 2015 10 1 10 001 11 ...

Page 33: ... using suitable wedges GNIL14TR04779AA 34 43 Support the engine at the back of the front axle 44 Position wedges between axle and support to prevent articulation GNIL14TR04781AA 35 45 Loosen the bolts securing the engine to the centre housing 46 Wheel the centre housing and rear wheels away from the engine GNIL14TR00753AA 36 47866583_ 02 12 2015 10 1 10 001 12 ...

Page 34: ...trical couplers 1 from Engine Con trol Unit ECU and 2 for rear lamps flasher unit fuse box etc GNIL14TR00757AA 37 48 Disconnect the steering hoses 1 GNIL14TR00758AA 38 49 Disconnect the hoses 1 from the intercooler GNIL14TR00702AA 39 50 Disconnect the pipes 1 from the fuel cooler GNIL14TR00703AA 40 47866583_ 02 12 2015 10 1 10 001 13 ...

Page 35: ...GNIL14TR00860AA 42 54 Support the front axle at the front bracket 55 Support the engine using a suitable hoist 56 Remove the buckle up bolts and set screws between the engine and front axle support Carefully lift the engine from the front axle support 57 Make sure that all the wires and tubes are discon nected Place the engine on a suitable stand for re pair GNIL14TR00755AA 43 47866583_ 02 12 2015...

Page 36: ...ngine and crankcase Engine Install For installation follow the reverse order of removal See Instrument cluster Install 55 408 for the instal lation of the instrument cluster 47866583_ 02 12 2015 10 1 10 001 15 ...

Page 37: ...Index Engine 10 Engine and crankcase 001 Engine Install 15 Engine Remove 3 47866583_ 02 12 2015 10 1 10 001 16 ...

Page 38: ...Engine 10 Crankshaft and flywheel 103 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 10 2 10 103 1 ...

Page 39: ...Contents Engine 10 Crankshaft and flywheel 103 SERVICE Engine flywheel Remove 3 Inspect 5 47866583_ 02 12 2015 10 2 10 103 2 ...

Page 40: ...ransmission housing to gain access to the clutch See engine removal section 1 Remove the bolts 1 Separate the transmission hous ing from engine GNIL14TR00753AA 1 2 Remove the bolts 1 which retains the clutch assembly to the engine fly wheel and slacken the two remaining bolts GNIL14TR00754AA 2 3 Insert centralizing pin special tool number 380000612 in clutch plate shaft seats back off the two rema...

Page 41: ...d take out the flywheel from the main clutch housing GNIL14TR00770AA 4 Clutch housing separation from the engine if necessary 6 Place a suitable support Remove the bolts 1 and separate the clutch housing GNIL14TR00771AA 5 47866583_ 02 12 2015 10 2 10 103 4 ...

Page 42: ...r ring gear using a ham mer and chisel to crack the ring gear 3 To reinstall a new ring gear heat the new ring gear to 120 150 C 245 300 F from the inside only Be careful not to overheat the ring gear teeth Use a temperature sensitive crayon to mark the inside of the ring gear Quench the ring gear quickly to obtain a good shrink fit onto the flywheel 20093403 1 47866583_ 02 12 2015 10 2 10 103 5 ...

Page 43: ...Index Engine 10 Crankshaft and flywheel 103 Engine flywheel Inspect 5 Engine flywheel Remove 3 47866583_ 02 12 2015 10 2 10 103 6 ...

Page 44: ...Engine 10 Air cleaners and lines 202 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 10 3 10 202 1 ...

Page 45: ...Contents Engine 10 Air cleaners and lines 202 SERVICE Air cleaner Remove 3 Disassemble 4 Inspect 5 Cleaning 6 Replace 7 Assemble 8 47866583_ 02 12 2015 10 3 10 202 2 ...

Page 46: ...s 1 Lift the front hood 2 Loosen the clamp 1 of air cleaner hose Remove the air cleaner hose GNIL14TR00720AA 1 3 Loosen the bolt of the air cleaner securing clamp 1 4 Remove the air cleaner assembly GNIL14TR00720AA 2 Air cleaner mounting bracket removal 5 Loosen the bolts and remove the air cleaner mounting bracket GNIL14TR00722AA 3 47866583_ 02 12 2015 10 3 10 202 3 ...

Page 47: ...the tractor It is not necessary to remove the complete assembly from the tractor 1 Release the locking clips 1 and remove the air cleaner cover 2 GNIL14TR00721AA 1 2 Remove the air cleaner outer element 1 GNIL14TR00723AA 2 3 Remove the inner element 1 GNIL14TR00724AA 3 47866583_ 02 12 2015 10 3 10 202 4 ...

Page 48: ... of the air cleaner housing using a damp lint free cloth on a probe Do not damage the inner filter element Ensure that the inner end of the housing is clean and smooth This ensures good seat ing of the rubber seal on the element 4 Install the cleaned outer element or new outer el ement Gently push it inside the housing in clockwise direction 5 While fitting back the cover make sure that the dust c...

Page 49: ...method B or maximum 900 h Inner element should be replaced after three outer element replacements or every 2700 h whichever is earlier NOTE Clean the air filters in a well ventilated room with a provision to artificially throw out the dusty air If it is not available it is advised to do the cleaning outdoors but never in an unventilated room Method A Lightly tap the element against the palm Contin...

Page 50: ...time of replacement It should never be cleaned The inner element should be replaced after three outer element replacements or 2700 h whichever is earlier 2 Follow the similar instructions of removing and fitting outer element from casting to replace inner element 47866583_ 02 12 2015 10 3 10 202 7 ...

Page 51: ...e Air cleaners and lines Air cleaner Assemble Fitment For assembly follow the reverse order of disassembly Clean the interior of the air filter housing using a clean cloth 47866583_ 02 12 2015 10 3 10 202 8 ...

Page 52: ...Engine 10 Air cleaners and lines 202 Air cleaner Assemble 8 Air cleaner Cleaning 6 Air cleaner Disassemble 4 Air cleaner Inspect 5 Air cleaner Remove 3 Air cleaner Replace 7 47866583_ 02 12 2015 10 3 10 202 9 ...

Page 53: ...47866583_ 02 12 2015 10 3 10 202 10 ...

Page 54: ...Engine 10 Fuel filters 206 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 10 4 10 206 1 ...

Page 55: ...Contents Engine 10 Fuel filters 206 SERVICE Pre filter Remove 3 Install 4 47866583_ 02 12 2015 10 4 10 206 2 ...

Page 56: ...hood 2 Remove the electrical connections on the fuel prefilter GNIL14TR00737AA 1 3 Disconnect all the fuel lines on the fuel prefilter GNIL14TR00712AA 2 4 Loosen the bolts 1 and remove the fuel prefilter GNIL14TR00862AA 3 47866583_ 02 12 2015 10 4 10 206 3 ...

Page 57: ...Engine Fuel filters Pre filter Install For installation follow the reverse order of removal 47866583_ 02 12 2015 10 4 10 206 4 ...

Page 58: ...Index Engine 10 Fuel filters 206 Pre filter Install 4 Pre filter Remove 3 47866583_ 02 12 2015 10 4 10 206 5 ...

Page 59: ...47866583_ 02 12 2015 10 4 10 206 6 ...

Page 60: ...Engine 10 Fuel tanks 216 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 10 5 10 216 1 ...

Page 61: ...Contents Engine 10 Fuel tanks 216 SERVICE Fuel cooler Remove 3 Install 4 47866583_ 02 12 2015 10 5 10 216 2 ...

Page 62: ...Lift the front hood 2 Remove the battery See Battery Remove 55 302 3 Disconnect the fuel pipes 1 on the fuel cooler GNIL14TR00703AA 1 4 1 Loosen all the bolts 1 2 Remove the fuel cooler 2 GNIL14TR00703AA 2 47866583_ 02 12 2015 10 5 10 216 3 ...

Page 63: ...er Install 1 Install the fuel cooler 1 and tighten the bolts 2 GNIL14TR00703AA 1 2 Connect the fuel pipes 1 on the fuel cooler GNIL14TR00703AA 2 3 Install the battery See Battery Install 55 302 47866583_ 02 12 2015 10 5 10 216 4 ...

Page 64: ...Index Engine 10 Fuel tanks 216 Fuel cooler Install 4 Fuel cooler Remove 3 47866583_ 02 12 2015 10 5 10 216 5 ...

Page 65: ...47866583_ 02 12 2015 10 5 10 216 6 ...

Page 66: ...Engine 10 Aftercooler 310 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 10 6 10 310 1 ...

Page 67: ...Contents Engine 10 Aftercooler 310 SERVICE Aftercooler Remove 3 Install 5 47866583_ 02 12 2015 10 6 10 310 2 ...

Page 68: ...eering oil reservoir 2 GNIL14TR00759AA 2 3 1 Disconnect the hose from the radiator coolant reser voir 2 Loosen the bolts 1 and remove the coolant reser voir GNIL14TR00757AA 3 4 1 Remove the electrical couplers on the Engine Con trol Unit ECU bracket 1 and the fuse box 2 2 Loosen the bolts 3 and remove the ECU bracket GNIL14TR00762AA 4 47866583_ 02 12 2015 10 6 10 310 3 ...

Page 69: ...ne Aftercooler 5 1 Remove the inlet 1 and the outlet hoses 2 of the after cooler 2 Loosen and remove the mounting bolts 3 and re move the after cooler 4 GNIL14TR00702AA 5 47866583_ 02 12 2015 10 6 10 310 4 ...

Page 70: ...1 2 1 Install the Engine Control Unit ECU and tighten the bolts 1 2 Connect the electrical couplers on the ECU 1 and fuse box GNIL14TR00762AA 2 3 1 Install the radiator coolant reservoir and tighten the bolts 1 2 Connect the hoses to the radiator coolant reservoir GNIL14TR00757AA 3 4 Install the steering oil reservoir 1 and tighten the bolt 2 GNIL14TR00759AA 4 47866583_ 02 12 2015 10 6 10 310 5 ...

Page 71: ...Engine Aftercooler 5 Connect the negative terminal 1 of the battery GNIL14TR00784AA 5 47866583_ 02 12 2015 10 6 10 310 6 ...

Page 72: ...Index Engine 10 Aftercooler 310 Aftercooler Install 5 Aftercooler Remove 3 47866583_ 02 12 2015 10 6 10 310 7 ...

Page 73: ...47866583_ 02 12 2015 10 6 10 310 8 ...

Page 74: ...Engine 10 Engine cooling system 400 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 10 7 10 400 1 ...

Page 75: ...Contents Engine 10 Engine cooling system 400 SERVICE Radiator Remove 3 Install 5 47866583_ 02 12 2015 10 7 10 400 2 ...

Page 76: ...er See Aftercooler Remove 10 310 and Fuel cooler Remove 10 216 3 Remove the cock 1 and drain the coolant from the radiator NOTE Remove the radiator cap to assist draining GNIL14TR00760AA 1 4 Loosen the clamp 1 on the air inlet hose Remove the bolts securing the air cleaner 2 to the radiator GNIL14TR00720AA 2 5 Loosen the bolts and remove the air cleaner mounting bracket GNIL14TR00860AA 3 47866583_...

Page 77: ...cooling system 6 Remove all the hoses from the radiator GNIL14TR00717AA 4 7 Loosen and remove all the radiator mounting bolts Re move the radiator from the tractor GNIL14TR00761AA 5 47866583_ 02 12 2015 10 7 10 400 4 ...

Page 78: ...Engine Engine cooling system Radiator Install For installation follow the reverse order of removal 47866583_ 02 12 2015 10 7 10 400 5 ...

Page 79: ...Index Engine 10 Engine cooling system 400 Radiator Install 5 Radiator Remove 3 47866583_ 02 12 2015 10 7 10 400 6 ...

Page 80: ...47866583_ 02 12 2015 10 7 10 400 7 ...

Page 81: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 82: ...SERVICE MANUAL Clutch Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 18 ...

Page 83: ...Contents Clutch 18 18 100 Clutch mechanical release control 18 1 18 110 Clutch and components 18 2 47866583_ 02 12 2015 18 ...

Page 84: ...Clutch 18 Clutch mechanical release control 100 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 18 1 18 100 1 ...

Page 85: ...Contents Clutch 18 Clutch mechanical release control 100 SERVICE Clutch mechanical release control Remove 3 Install 7 Adjust 8 47866583_ 02 12 2015 18 1 18 100 2 ...

Page 86: ...e goggles gloves and safety footwear Failure to comply could result in minor or moderate injury C0145A 1 Remove all foot platform bolts and remove the left hand side footboard See Protections and foot boards Remove 90 118 GNIL14TR00767AA 1 2 Remove clutch pedal spring 1 3 Remove the split pin 2 4 Remove the roll pin 3 5 Disconnect the linkage 4 6 Remove the circlip 5 GNIL14TR00766AA 2 7 Loosen the...

Page 87: ... brake pedal spring 2 and discon nect all the linkages GNIL14TR00782AA 5 11 Jack up rear left hand side of tractor and remove left hand side rear wheel GNIL14TR04667AB 6 12 Pull out clutch or brake pedal support rod 1 from the rear axle housing 13 Retrieve clutch pedal 2 from the support shaft GNIL14TR04668AB 7 47866583_ 02 12 2015 18 1 18 100 4 ...

Page 88: ...ss shaft GNIL14TR00781AA 8 2 Remove the split pin lock 1 take out the pin and remove hand lever from the mounting bracket 3 Remove bolt 2 from the housing to take out the levers with the bracket GNIL14TR04671AB 9 Cross shafts removal To remove cross shafts clutch housing has to be split between engine flywheel housing and transmission housing 1 Remove clips 1 from both the forks and release bearin...

Page 89: ...ock screw 1 GNIL14TR04675AB 12 4 Pull out the Power Take Off PTO cross shaft 1 from left hand side of transmission housing and retrieve fork from the housing GNIL14TR04677AB 13 5 Loosen the transmission clutch fork screw 6 Pull out the Transmission clutch cross shaft 1 from left hand side of the transmission housing and retrieve fork from the housing GNIL14TR04676AB 14 47866583_ 02 12 2015 18 1 18...

Page 90: ... clutch release forks 3 Comply with tightening torques indicated See Clutch Torque 18 110 GNIL14TR04673AB 1 4 Apply LOCTITE 243 sealant to clutch release fork lock screw and left hand side brake pedal lock screw before tightening 5 Thoroughly clean and degrease mating surfaces of en gine and transmission housing Apply a bead of liquid gasket of approximately 2 000 mm 0 079 in of diam eter Buckle u...

Page 91: ...shaft GNIL14TR04688AB 2 Power Take Off PTO clutch lever free play double speed 1 Remove the pin 2 fork 3 and rod 5 separately 2 Keep lever 1 at the right most position such that the bearing just touches the clutch fingers 3 Insert rod 5 into fork 6 and tight the threads up to 15 00 mm 0 59 in 4 Keep end of lever 7 at 30 00 35 00 mm 1 18 1 38 in from edge as shown in figure 5 Keep the rod in static...

Page 92: ...l 8 Now tight the nut 4 to lock the fork 9 We can see the play of lever 7 between edge A and end of lever at 30 00 35 00 mm 1 18 1 38 in from edge A This is the free play of Power Take Off PTO clutch lever 47866583_ 02 12 2015 18 1 18 100 9 ...

Page 93: ...tch 18 Clutch mechanical release control 100 Clutch mechanical release control Adjust 8 Clutch mechanical release control Install 7 Clutch mechanical release control Remove 3 47866583_ 02 12 2015 18 1 18 100 10 ...

Page 94: ...Clutch 18 Clutch and components 110 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 18 2 18 110 1 ...

Page 95: ...que 3 Special tools 4 Sealing 4 FUNCTIONAL DATA Clutch Dynamic description 6 Sectional view 7 SERVICE Clutch Remove 9 Disassemble 10 Inspect 13 Assemble 15 Adjust 16 Service instruction 17 Clutch control mechanism Remove 18 DIAGNOSTIC Clutch Troubleshooting 20 47866583_ 02 12 2015 18 2 18 110 2 ...

Page 96: ...terial Cerametallic Plate thickness 7 50 8 10 mm 0 30 0 32 in Plate with pressure springs Tangential springs Clutch Torque Description Thread Size mm Torque Transmission housing to flywheel housing buckle up bolts C1 M12 X 1 25 7 00 kgf 15 43 lbf Clutch assembly mounting bolts C2 M8 X 1 2 60 kgf 5 73 lbf Bolts release fork C3 M16 X 1 5 16 00 kgf 35 27 lbf 47866583_ 02 12 2015 18 2 18 110 3 ...

Page 97: ... gauge 380000612 Clutch finger height adjusting wrench set of three 380000256 Installer oil seal in clutch housing 84261387 Installer oil seal in hollow shaft 84261388 Clutch Sealing Operation description Sealant specification Engine to transmission buckle up S1 LOCTITE 518 Bolts release fork S2 LOCTITE 243 47866583_ 02 12 2015 18 2 18 110 4 ...

Page 98: ...Clutch Clutch and components GNIL14TR04659GB 1 47866583_ 02 12 2015 18 2 18 110 5 ...

Page 99: ...ch housing by the spring action of dish ring The friction between the clutch disc flywheel and clutch housing transmits the engine power to the transmission drive shaft and PTO drive shaft independently The clutch pedal is connected to the main clutch release bearing by means of mechanical linkage components When the clutch pedal is pressed the clutch release bearing moves forward and discharges t...

Page 100: ...Clutch Clutch and components Clutch Sectional view GNIL14TR00802GA 1 1 Damper springs 3 Power Take Off PTO clutch release fingers 2 Transmission clutch release fingers 47866583_ 02 12 2015 18 2 18 110 7 ...

Page 101: ...Clutch Clutch and components GNIL14TR00803GA 2 1 Clutch facing 4 Idle damper spring 2 Facing rivet 5 Main damper spring 3 Hub 47866583_ 02 12 2015 18 2 18 110 8 ...

Page 102: ... tractor between engine and transmission housing to gain access to the clutch 1 Remove the bolts 1 2 Separate the transmission housing from engine See engine removal section GNIL14TR00753AA 1 3 Remove the bolts 1 which retains the clutch assem bly to the engine fly wheel and slacken the two remain ing bolts GNIL14TR00754AA 2 4 Insert centralizing pin special tool number 380000612 in clutch plate s...

Page 103: ...n death or serious injury W0208A 1 Remove the clutch assembly from the tractor as de scribed earlier in this section See Clutch Remove 18 110 2 Loosen the Power Take Off PTO clutch release lever locknuts 1 NOTICE Since the locknuts are under the load of disk ring loosen all these gradually and evenly by rotating 1 4 to 1 2 turns GNIL14TR04695AB 1 3 Remove Power Take Off PTO pressure plate 1 GNIL14...

Page 104: ...ve transmission clutch pressure plate 1 GNIL14TR04699AB 5 7 Remove transmission clutch disc 1 from the housing GNIL14TR04700AB 6 Release fingers disassembly 8 Push out the pin 1 from the housing and retrieve the spring 2 GNIL14TR04702AB 7 47866583_ 02 12 2015 18 2 18 110 11 ...

Page 105: ...Clutch Clutch and components 9 Remove release fingers from the housing GNIL14TR04703AA 8 47866583_ 02 12 2015 18 2 18 110 12 ...

Page 106: ...o to be replaced if the organic facings are found to be soaked with oil 3 Check condition of clutch housing and pressure plate friction surfaces If necessary dress noting that dimen sions of pressure plates and clutch housing must not be reduced below the limits described below otherwise replace as necessary 20097548 1 47866583_ 02 12 2015 18 2 18 110 13 ...

Page 107: ... Power Take Off PTO clutch disc thickness S2 Transmission clutch disc thickness P Spring dimensions to restore original load 4 500 mm 0 180 in fixed Check that value F is equal to 69 850 70 150 mm 2 750 2 760 in In restoring value F check that clutch housing thick ness E does not fall below 17 000 mm 0 670 in i e D F E 17 000 mm 0 670 in Check that the undercut E on clutch housing is deeper than 2...

Page 108: ... springs 1 correctly and lock ring 2 on transmission pressure plates as shown in 1 GNIL14TR04706AB 1 2 Use special tool number 380000612 and centralize the clutch discs 3 Install the clutch assembly on flywheel 4 Adjust the release fingers as described under clutch release finger settings See Clutch Adjust 18 110 47866583_ 02 12 2015 18 2 18 110 15 ...

Page 109: ...h fingers height setting gauge drive shaft seats ensuring that end is in contact with flywheel housing 3 First set Power Take Off PTO release fingers by us ing height setting gauge as shown in figure Gap be tween gauge and finger should be between 0 30 mm 0 01 in Use feeler gauge to check the gap 4 Use special tool no 9971365 Rotate the locknut and set the gap 5 Similarly set the height setting ga...

Page 110: ...at the clutch cover is secured to the fly wheel evenly and sequentially Use new spring wash ers 6 After an initial running in period any variation lever height will correct itself 7 Before fitting check the clutch plate for lateral runout 8 Make sure that the clutch plate is fitted the correct way Observe the direction as indicated on the driven plate 9 Check the gearbox input shaft for damage Onl...

Page 111: ...nd safety footwear Failure to comply could result in death or serious injury W0208A It is necessary to split the tractor between engine and transmission housing to gain access to the clutch 1 Loosen the set screw 1 from fork 2 Pull out the cross shaft 2 3 Remove clutch release fork 3 GNIL14TR04679AB 1 4 Slide out the clutch release bearing 1 GNIL14TR04680AB 2 5 Loosen the bolts 3 numbers as shown ...

Page 112: ...se plastic ham mer to push out the shaft The shaft will come out to ward gearbox side Retrieve bearing GNIL14TR04683AB 5 8 To remove shaft 2 toward the clutch side remove cir clip lock 1 Retrieve bearing and seal GNIL14TR04684AA 6 9 Use special tool number 84261387 and install the seal 1 GNIL14TR04685AB 7 47866583_ 02 12 2015 18 2 18 110 19 ...

Page 113: ...aterial Replace clutch disc repair leak of lubricant in to clutch housing thoroughly clean fric tion surfaces Finger springs broken Replace finger springs Clutch fails to disconnect and drags Warped clutch disc Replace clutch disc Damaged clutch release bearing Replace clutch release bearing Damaged finger spring Replace finger springs Clutch noise at engagement and or disengagement Warped clutch ...

Page 114: ... Clutch Dynamic description 6 Clutch General specification 3 Clutch Inspect 13 Clutch Remove 9 Clutch Sealing 4 Clutch Sectional view 7 Clutch Service instruction 17 Clutch Special tools 4 Clutch Torque 3 Clutch Troubleshooting 20 Clutch control mechanism Remove 18 47866583_ 02 12 2015 18 2 18 110 21 ...

Page 115: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 116: ...SERVICE MANUAL Transmission Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 21 ...

Page 117: ...1 114 Mechanical transmission 21 1 21 130 Mechanical transmission external controls 21 2 21 140 Mechanical transmission internal components 21 3 21 145 Gearbox internal components 21 4 21 200 Dropbox 21 5 47866583_ 02 12 2015 21 ...

Page 118: ...Transmission 21 Mechanical transmission 114 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 21 1 21 114 1 ...

Page 119: ...ools 6 FUNCTIONAL DATA Mechanical transmission Sectional view 7 Overview 9 SERVICE Mechanical transmission Drive shaft Service instruction 12 Remove 14 Disassemble Intermediate plate 18 Inspect Intermediate plate 21 Assemble Intermediate plate 22 Install 25 DIAGNOSTIC Mechanical transmission Troubleshooting 29 47866583_ 02 12 2015 21 1 21 114 2 ...

Page 120: ...56 25 10 RH4 32 40 34 53 Mechanical transmission Torque Description Thread size Torque Gear shift lever cover bolts C1 M8 2 5 kgf 5 5 lbf Hydraulic housing on transmission retainer bolts C2 M10 x 1 25 6 0 kgf 13 2 lbf Hydraulic housing on transmission retainer bolts C3 M12 x 1 25 10 0 kgf 22 0 lbf Crown wheel bolts C4 M10 6 0 kgf 13 2 lbf Pinion lock nut C5 M35 30 0 kgf 66 1 lbf Drain plug C6 M22 ...

Page 121: ...Transmission Mechanical transmission GNIL14TR00824GA 1 47866583_ 02 12 2015 21 1 21 114 4 ...

Page 122: ...sion housing S1 LOCTITE 518 Gear shift lever cover S2 LOCTITE 518 Power Take Off PTO cover plate S3 LOCTITE 518 Crown wheel bolts S4 LOCTITE 243 Front cover plate S5 LOCTITE 518 Front cover bolts S6 LOCTITE 243 Transmission to centre housing S7 LOCTITE 518 Lift housing to transmission housing S8 LOCTITE 518 47866583_ 02 12 2015 21 1 21 114 5 ...

Page 123: ...nical transmission Special tools Tool description Tool number Socket pinion check nut 84261389 Yoke and spreader 291051 and 291052 Pinion locking tool 380002985 Mandrel with extension 9971381 Special snap ring remover 84261393 47866583_ 02 12 2015 21 1 21 114 6 ...

Page 124: ... 9 1st 2nd Synchrokit 2 Range shaft 10 3rd 4th Synchrokit 3 Power Take Off PTO input shaft 11 Hi Lo gear coupler 4 1st gear 12 Low gear on range shaft 5 2nd gear 13 Cluster gear 6 3rd gear 14 Pinion shaft 7 4th gear 15 Driven shaft 8 Low gear on pinion shaft 16 Reverse gear 47866583_ 02 12 2015 21 1 21 114 7 ...

Page 125: ...827GA 2 17 Reverse drive gear 21 Range gear shift lever 18 Range gear shift fork 22 1st 2nd gear shift fork 19 Reverse intermediate gear 23 3rd 4th gear shift fork 20 Hi Lo gear shift lever 24 Hi Lo gear shift fork 47866583_ 02 12 2015 21 1 21 114 8 ...

Page 126: ...top the tractor and move the Hi Low selector lever backward for high or forward for low To change the gears in the selected range depress the clutch pedal and shift main gear lever in the normal way To select reverse gear R first stop the tractor NOTE A safety start switch prevents operation of the starter motor unless the transmission range lever is in neutral position N NOTE If it is necessary t...

Page 127: ...and speed of the pinion shaft varies according to the number of teeth on the gears 6 and 7 Range gear can be selected by shifting the range gear coupler 11 to left or right For getting high range shifting coupler to left engages cluster gear directly to pinion shaft and pinion shaft receives the rotation from any one of the gears 1st 2nd 3rd and 4th depending on the position of gear couplers 9 and...

Page 128: ...long the left side of the trans mission The switch is activated by the range shift lever When the range is in neutral the switch is closed to allow current to flow to the neutral start relay NOTE The range shift rail operates the safety switch Notches in the shift rail accept the balk pin extending the plunger in the safety switch when the range lever is in the neutral position This completes the ...

Page 129: ...It is very important to use proper lubricants and to main tain a constant level of correct lubrication Right operational temperature is to be maintained Shaft seals Respect the following recommendations during seal and gasket assembly Clean shaft very carefully and ensure that the part in contact with the rings is not damaged cut or out of roundness Assemble the seals so that the lips is fitted to...

Page 130: ...voided 3 Do not wash with stream or hot water as it will be very difficult to eliminate surface humidity 4 Dry all parts with a rag or air jet to avoid scratching from abrasive residuals 5 All surfaces should be covered with lubricant so as to protect it from future oxidation Inspections 1 Examine accurately that all bearings external rings which may be still stuck in their position pivot pins on ...

Page 131: ...itable slings or hooks Make sure the work area is clear of all bystanders Failure to comply will result in death or serious injury D0076A NOTE To remove the transmission housing from the tractor tractor has to be split at clutch and transmission housing Fenders hydraulic housing three point linkage rear tires and final drive housing have to be removed from the tractor 1 Loosen the bolts and remove...

Page 132: ...move both the left hand and right hand side wheels GNIL14TR04016AB 4 5 Loosen the bolts 1 and remove fenders from both sides Drain oil from transmission housing GNIL14TR00790AA 5 6 Disconnect all the hydraulic lines 7 Remove three point linkages from the tractor GNIL14TR00562AA 6 47866583_ 02 12 2015 21 1 21 114 15 ...

Page 133: ...ce a suitable stand under both side of the final drive housing 10 Loosen the bolts 1 disconnect the wiring and re move operator s seat GNIL14TR04021AB 8 11 Loosen the transmission and centre housing coupling bolts 1 Use a suitable hoist and lift the assembly GNIL14TR04022AB 9 12 Loosen bolts 1 and remove top cover along with gearshift levers GNIL14TR04124AB 10 47866583_ 02 12 2015 21 1 21 114 16 ...

Page 134: ...rap chain or nylon rope on the final drive housing and connect it to a hoist Loosen the attaching bolts and remove the final drive housing 16 Repeat for the final drive housing on the other side 17 Loosen the bolts securing hydraulic housing on trans mission housing and lift the housing using suitable hoist GNIL14TR04026AA 13 18 Place transmission housing on a suitable stand GNIL14TR04027AA 14 478...

Page 135: ... could result in minor or moderate injury C0044A To remove the intermediate plate and reverse gear 1 Remove Power Take Off PTO shaft 1 GNIL14TR04150AB 1 2 Remove all roll pins from gear rails to make dismantling easy Remove the springs and balls NOTE Remove plug 1 from housing as shown at 2 from where Hi Low rail passes retrieve spring and ball 3 of Hi Low rail Retrieve balls and springs from loca...

Page 136: ...crew the reverse intermediate gear shaft locking screw 1 with a screw driver 2 8 Remove the idler gear 3 GNIL14TR04135AB 5 9 Remove the spacer 1 needle bearing 2 and re verse intermediate gear pin 3 along with reverse in termediate gear 4 GNIL14TR04136AB 6 10 Remove the snap ring 1 securing the driven shaft bearing GNIL14TR04137AB 7 47866583_ 02 12 2015 21 1 21 114 19 ...

Page 137: ...ring the intermediate plate GNIL14TR04138AB 8 12 Remove the intermediate plate 1 along with the bear ings GNIL14TR04139AB 9 13 Remove the ball bearings from the intermediate plate by expanding the retaining rings 1 GNIL14TR04140AB 10 47866583_ 02 12 2015 21 1 21 114 20 ...

Page 138: ...ransmission Mechanical transmission Inspect Intermediate plate Clean and inspect the shift fork shift rail coupler hub bearings and gears for excessive wear and or damage Replace if necessary 47866583_ 02 12 2015 21 1 21 114 21 ...

Page 139: ...use suitable tools to align mating parts DO NOT use your hand or fingers Failure to comply could result in minor or moderate injury C0044A 1 Install the retaining rings 1 into the intermediate plate GNIL14TR04141AB 1 2 Expand the retaining ring 1 and insert the bearing Use a hammer to drive the bearing in until the retaining ring locks into the groove on the bearing 3 Install the intermediate plat...

Page 140: ...verse intermediate gear pin 3 along with the reverse inter mediate gear 4 GNIL14TR04145AB 5 7 Use thread locker LOCTITE 243 for locking reverse intermediate gear 1 shaft screw GNIL14TR04146AB 6 8 Install the reverse drive gear 1 onto the drive shaft 9 Secure the reverse drive gear 1 with the snap ring 2 GNIL14TR04147AB 7 47866583_ 02 12 2015 21 1 21 114 23 ...

Page 141: ...l all roll pins to shift rails along with springs and detent balls NOTE Install the detent balls and springs where shown 1 and 2 Insert the Hi Low rail detent ball and spring 3 where shown 4 Install the plug 5 above the Hi Low rail detent ball and spring at 4 GNIL14TR04149AB 9 12 Install the Power Take Off PTO shaft 1 GNIL14TR04150AB 10 47866583_ 02 12 2015 21 1 21 114 24 ...

Page 142: ... 3 Repeat procedure for other side GNIL14TR04129AA 1 4 Using a suitable lifting device install the hydraulic housing onto the rear of the transmission housing 5 Remove the complete transmission assembly from the stand using a suitable device 6 Attach the transmission housing to the clutch housing and secure with the M12 attaching bolts 1 from re moval Torque the bolts to 88 00 N m 778 87 lb in GNI...

Page 143: ... lines 11 Install the ROPS to the axle housings Secure using the bolts and nuts 1 GNIL14TR04017AB 6 12 Install the rear fenders 1 GNIL14TR00790AA 7 13 Install both left hand and right hand side wheels 1 GNIL14TR04159AB 8 14 Remove the jack stands 1 and splitting trolley 2 15 Install the three point linkages 1 to the tractor 47866583_ 02 12 2015 21 1 21 114 26 ...

Page 144: ...inkage 1 NOTE Check the clutch pedal free play and adjust as nec essary NOTE Connect the brake linkage rods to the brake pedals GNIL14TR04164AB 10 18 Connect the wire harness connector 1 between left hand and right hand side fenders GNIL14TR04165AB 11 19 Connect the electrical couplings 1 GNIL14TR00797AA 12 47866583_ 02 12 2015 21 1 21 114 27 ...

Page 145: ...Transmission Mechanical transmission 20 Connect the negative battery cable 1 to the negative battery terminal GNIL14TR00784AA 13 GNIL14TR04168GB 14 47866583_ 02 12 2015 21 1 21 114 28 ...

Page 146: ...o cor rect level Noisy operation with tractor stationery idling engine and transmission in neutral Faulty clutch plate springs Replace clutch plates Self disengagement of speed range gears External linkage and levers mis adjusted Adjust correctly Failed control rail retaining springs Replace springs Partial engagement travel Correct reasons for problem and restore full travel Difficult engagement ...

Page 147: ...mission General specification 3 Mechanical transmission Inspect Intermediate plate 21 Mechanical transmission Install 25 Mechanical transmission Overview 9 Mechanical transmission Remove 14 Mechanical transmission Sealing 5 Mechanical transmission Sectional view 7 Mechanical transmission Special tools 6 Mechanical transmission Torque 3 Mechanical transmission Troubleshooting 29 47866583_ 02 12 201...

Page 148: ...Transmission 21 Mechanical transmission external controls 130 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 21 2 21 130 1 ...

Page 149: ...nsmission 21 Mechanical transmission external controls 130 SERVICE Mechanical transmission external controls Remove 3 Adjust 4 Transmission control levers Disassemble 5 Install 8 47866583_ 02 12 2015 21 2 21 130 2 ...

Page 150: ... range safety switch 1 Disconnect the negative battery terminal 2 Disconnect the transmission range safety switch 1 from the tractor wire harness NOTE Switch is protected with a rubber boot 3 Unscrew the switch 2 1 with sealing washer from the transmission housing GNIL14TR00793AA 1 47866583_ 02 12 2015 21 2 21 130 3 ...

Page 151: ...ly 26 000 mm 1 024 in adjust if required GNIL14TR04225AB 1 2 At the opposite cable end count the number of visible threads B there should be 6 or 7 Thread length can be changed by adjusting the nuts on either side of cable mounting bracket C 3 Adjust the nuts so that the shuttle lever starts to move when clutch pedal is depressed beyond free play 50 00 55 00 mm 1 97 2 17 in from rest and then tigh...

Page 152: ...eath or serious injury W0208A CAUTION Pinch hazard Always use suitable tools to align mating parts DO NOT use your hand or fingers Failure to comply could result in minor or moderate injury C0044A 1 Loosen the bolts 1 and remove the top cover 2 from the transmission housing GNIL14TR00804AA 1 2 Remove the circlip 1 Remove the gear lever rubber boot 2 GNIL14TR04091AB 2 Main gear selector lever 3 Rem...

Page 153: ... 2 GNIL14TR00807AA 4 5 Loosen the bolt and remove the yoke 1 GNIL14TR00809AA 5 6 Remove the split pins 1 and take out pin 2 to remove range gear selector lever 3 GNIL14TR04092AB 6 Range gear selector lever 7 Remove the circlip lock 1 from the yoke 2 GNIL14TR04093AB 7 47866583_ 02 12 2015 21 2 21 130 6 ...

Page 154: ...linkage 2 NOTE Take out springs 2 numbers from the range lever GNIL14TR04094AB 8 9 Remove the expansion plug 1 from the shifter cover housing as shown GNIL14TR04095AB 9 10 Remove the roll pin 1 from the shaft 2 Remove the fork 3 GNIL14TR04096AB 10 47866583_ 02 12 2015 21 2 21 130 7 ...

Page 155: ...spect the rubber boot 1 for cracks or damage re place if necessary 2 Reinstallation follows the removal procedure in re verse from step 7 back to step 1 GNIL14TR00785AA 1 3 Before fixing cover plate thoroughly clean and degrease mating surface and apply a 2 000 mm 0 079 in bead of sealant following the pattern shown in 2 4 Torque the bolts to the correct value GNIL14TR04099FB 2 47866583_ 02 12 201...

Page 156: ...sion external controls 130 Mechanical transmission external controls Adjust 4 Mechanical transmission external controls Remove 3 Transmission control levers Disassemble 5 Transmission control levers Install 8 47866583_ 02 12 2015 21 2 21 130 9 ...

Page 157: ...47866583_ 02 12 2015 21 2 21 130 10 ...

Page 158: ...Transmission 21 Mechanical transmission internal components 140 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 21 3 21 140 1 ...

Page 159: ...Contents Transmission 21 Mechanical transmission internal components 140 SERVICE Transmission internal parts Install Transmission rails and fork 3 47866583_ 02 12 2015 21 3 21 140 2 ...

Page 160: ...he seat in housing GNIL14TR04227AB 1 2 The Hi low shift rail 1 shift fork and shift gate should be installed after the pinion and crown settings NOTE Keep grooves of rails upward to make easy fitment of balls and springs GNIL14TR04228AB 2 3 Transmission shift rails can be identified by referring to Figure 3 To fit rails 1st 2nd 1 and 3rd 4th 2 rails are similar After fitting range shaft and drive ...

Page 161: ...nd rail shaft on the notch of 1st 2nd gear fork 200900175 5 6 Insert the ball 1 applying some grease in housing after removing bolt as shown in 4 7 Insert the 1st 2nd rail 2 passing thru gate as shown in 5 NOTE Keep grooves of rails upward to make easy fitment of balls and springs 200900174 6 8 Insert the ball and pin 1 after removing neutral safety switch for Hi Lo rail then fit neutral safety sw...

Page 162: ...e rail insert ball 1 applying some grease in the housing as such it sits in groove given on reverse rail 10 Insert the balls 1 and springs 2 of the rails Insert plug above the spring of Hi Lo rail Fit roll pins 3 in all rails and gates 20099991 8 47866583_ 02 12 2015 21 3 21 140 5 ...

Page 163: ...Index Transmission 21 Mechanical transmission internal components 140 Transmission internal parts Install Transmission rails and fork 3 47866583_ 02 12 2015 21 3 21 140 6 ...

Page 164: ...Transmission 21 Gearbox internal components 145 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 21 4 21 145 1 ...

Page 165: ...ts 145 SERVICE Gearbox internal components Remove 3 Inspect 7 Install 8 Drive shaft Remove 14 Disassemble 17 Inspect 18 Driven shaft Remove 19 Disassemble 21 Inspect 22 Install Transmission drive and driven shafts 23 47866583_ 02 12 2015 21 4 21 145 2 ...

Page 166: ...mission synchronizer kit and cluster gear 1 Remove the split pins to release the link 2 Remove the circlip lock 1 GNIL14TR04196AB 1 3 Remove the shuttle wire 1 as shown GNIL14TR04197AB 2 4 Collect the spring and the pin 1 as shown GNIL14TR04198AB 3 47866583_ 02 12 2015 21 4 21 145 3 ...

Page 167: ...move the detent ball 1 from the hole in the clutch housing GNIL14TR04201AB 6 8 Remove the roll pin 1 aligning the shaft link rod 2 and lever link rod 3 9 Slide the shaft link rod 2 out from the lever link rod 3 and remove the shaft link rod 2 from the cluster housing 10 Remove the lever link rod 3 from the shift fork 4 11 Remove the O rings from the shaft link rod 2 GNIL14TR04202AB 7 47866583_ 02 ...

Page 168: ...clip 1 from the groove of the input shaft 15 Remove the shuttle coupler gear assembly from the input shaft GNIL14TR04204AB 9 16 Remove the external retaining ring 1 from the groove of coupler shuttle gear 2 17 Remove the ball bearing 3 inside the coupler shuttle gear 2 GNIL14TR04205AB 10 18 Remove the snap ring 1 from the groove of the input shaft GNIL14TR04206AB 11 47866583_ 02 12 2015 21 4 21 14...

Page 169: ... rail 3 GNIL14TR04207AB 12 20 Remove the reverse gear 1 GNIL14TR04208AB 13 21 Remove the ball bearing 1 from the rear of the clutch housing 22 Remove the oil trench plate 2 from the housing sur face by loosening the M8 bolts and washers 3 GNIL14TR04209AB 14 47866583_ 02 12 2015 21 4 21 145 6 ...

Page 170: ...ngs by hand and check for any roughness Replace as necessary 3 Inspect the synchronizer gears and cluster gear shaft for excess wear chipped gear teeth cracks or any other damage Replace as necessary 4 Inspect the shift fork for wear or damage Replace as necessary 5 Inspect the detent grooves in the shift rail for excess wear Replace as necessary 6 Check the detent spring for wear or weak spring t...

Page 171: ... 3 through the shift fork 1 NOTE Secure the spring and detent ball against the groove on the shift rail by installing the shuttle detent bolt on the left hand side of the clutch housing 6 Install roll pin 4 after aligning the hole of the shift fork 1 and shift rail 3 7 Install the synchronizer kit 1 onto the spline of the input shaft 8 Secure the synchronizer on the input shaft with the ex ternal ...

Page 172: ... ball bearing installed from step 2 GNIL14TR04216AB 6 15 Apply petroleum jelly to the O rings 1 16 Insert the O rings in the grooves on the shaft link rod 2 GNIL14TR04217AB 7 17 Insert the shaft link rod 1 through the hole in the clutch housing 18 Insert the lever link rod 2 in the shift fork 4 19 Slide the shaft link rod 1 into the lever link rod 2 20 Align the holes in the shaft link rod 1 with ...

Page 173: ...nto the clutch housing 23 Install the shuttle detent bolt to the left hand side of the clutch housing GNIL14TR04220AB 10 24 Insert the pin and spring 1 to shuttle cable 2 GNIL14TR04221AB 11 25 Insert the shuttle cable 1 through the hole on the left hand side of the clutch housing GNIL14TR04222AB 12 47866583_ 02 12 2015 21 4 21 145 10 ...

Page 174: ...orks follow the proce dure as mentioned below 29 Insert shuttler rail 30 Insert the bottom shift rail 1 and 1st 2nd gearshift fork Insert the snap ring 2 on the bottom shift rail and ensure it sits on the seat in housing GNIL14TR04227AB 14 31 The Hi Low shift rail 1 shift fork and shift gate should be installed after the pinion and crown settings NOTE Keep grooves of rails upward to make easy fitm...

Page 175: ...of 3rd 4th gear GNIL14TR04229AB 16 33 After fitting reverse rail insert ball 1 applying some grease in the housing GNIL14TR04230AB 17 34 Insert the rail 1 of 3rd 4th with gate 2 passing through fork 3 of 3rd 4th gear as shown in figure 18 GNIL14TR04231AA 18 35 Insert gate of 1st 2nd rail shaft on the notch of 1st 2nd gear fork 36 Insert the ball 1 applying some grease in housing after removing bol...

Page 176: ...moving neutral safety switch for Hi Low rail then fit neutral safety switch and tighten it GNIL14TR04230AB 20 39 After fitting reverse rail insert ball 1 applying some grease in the housing as such it sits in groove given on reverse rail 40 Insert the balls 1 and springs 2 of the rails Insert plug above the spring of Hi Low rail Fit roll pins 3 in all rails and gates GNIL14TR04234AB 21 47866583_ 0...

Page 177: ... from the trans mission housing NOTE 1st and 2nd gear are a integral part of the drive shaft GNIL14TR04174AB 1 2 Remove shims GNIL14TR04175AB 2 3 Remove the snap ring 1 securing the 4th gear drive gear 2 on the range shaft GNIL14TR04176AB 3 4 Remove the 4th gear drive gear 1 from the range shaft GNIL14TR04177AB 4 47866583_ 02 12 2015 21 4 21 145 14 ...

Page 178: ...eplace as necessary 8 Inspect the shift rail for wear or damage Replace as necessary GNIL14TR04178A 5 Range shaft removal 9 Remove the circlip lock 1 of the range shaft GNIL14TR04065AB 6 10 Remove the range shaft 1 from the housing Re move the oil feeder cup 2 from the shaft as shown GNIL14TR04066AB 7 11 After removing the high low rail take out high low fork 1 NOTE It is required to take out the ...

Page 179: ...Transmission Gearbox internal components 12 Remove the range shaft Remove the snap ring 1 of range shaft bearing Remove the range shaft bearing GNIL14TR04068AB 9 47866583_ 02 12 2015 21 4 21 145 16 ...

Page 180: ...ng 1 from the drive shaft to remove the hub along with coupler GNIL14TR04179AB 1 GNIL14TR04180AA 2 2 Remove the snap ring 1 from the drive shaft Remove the 3rd drive gear 2 NOTE 1st and 2nd gear are a integral part of the drive shaft GNIL14TR04181AB 3 47866583_ 02 12 2015 21 4 21 145 17 ...

Page 181: ...uitable cleaning solution and allow to air dry 2 Inspect all gears for excess wear chipped gear teeth cracks or any other damage Replace as necessary 3 Inspect the gear coupler and synchromesh drive shaft for any cracks or damage Replace as necessary 47866583_ 02 12 2015 21 4 21 145 18 ...

Page 182: ...Remove the 1st gear 1 off the synchromesh driven shaft GNIL14TR04170AB 2 3 Remove the snap ring 1 from the driven shaft Take out the 1st 2nd gear shift fork 2 the 1st 2nd gear cou pler 3 and the hub 4 of the driven shaft NOTE Keep the face of the hub with the cut towards the pinion side GNIL14TR00867AA 3 4 Remove the snap ring 1 that secures the 2nd gear GNIL14TR04172AB 4 47866583_ 02 12 2015 21 4...

Page 183: ...Transmission Gearbox internal components 5 Remove the 2nd gear 1 from driven shaft GNIL14TR04173AB 5 47866583_ 02 12 2015 21 4 21 145 20 ...

Page 184: ...emble Dismantling on bench 1 Remove the snap ring 1 to remove the high gear 2 and bearing 3 from the synchromesh driven shaft GNIL14TR04182AB 1 NOTE 3rd and 4th gear are a integral part of the driven shaft 1 GNIL14TR04183AB 2 47866583_ 02 12 2015 21 4 21 145 21 ...

Page 185: ...re marks dis coloration from overheating or other damage Rotate the bearing by hand and check for any roughness while turning Replace as necessary 3 Inspect all the gears and driven shaft for excess wear chipped gear teeth cracks or any other damage Re place as necessary 4 Inspect synchronizer ring spring loaded poppet valve dog for wear 47866583_ 02 12 2015 21 4 21 145 22 ...

Page 186: ...riven shaft and pin ion keeping larger diameter towards driven shaft before fitting driven shaft on pinion GNIL14TR04184AB 1 2 Install the driven shaft 1 into the housing NOTE 3rd and 4th gears are a integral part of the driven shaft GNIL14TR04185AB 2 3 Install the 4th gear drive gear 1 onto the range shaft GNIL14TR04186AB 3 4 Secure the 4th gear drive gear 1 with the snap ring 2 GNIL14TR04187AB 4...

Page 187: ...ive shaft 1 and retain with snap ring 2 GNIL14TR04189AB 6 7 Install the synchromesh drive shaft 1 in assembled form which includes the drive shaft 3rd gear drive gear 2 and 3rd 4th gear coupler 3 NOTE 1st and 2nd gear are a integral part of the drive shaft GNIL14TR04190A 7 8 Install synchronizer ring GNIL14TR04191AB 8 47866583_ 02 12 2015 21 4 21 145 24 ...

Page 188: ...oupler 2 onto the driven shaft and insert the shift fork 3 onto the cou pler Secure the hub with the snap ring 4 NOTE Keep the face of the hub with the cut towards the pinion side GNIL14TR04193AB 10 11 Secure the shift fork in place by inserting the bottom shift rail 1 NOTE Insert the M12 plug 2 for the shift rail into the hous ing GNIL14TR04194AB 11 47866583_ 02 12 2015 21 4 21 145 25 ...

Page 189: ...Drive shaft Remove 14 Driven shaft Disassemble 21 Driven shaft Inspect 22 Driven shaft Install Transmission drive and driven shafts 23 Driven shaft Remove 19 Gearbox internal components Inspect 7 Gearbox internal components Install 8 Gearbox internal components Remove 3 47866583_ 02 12 2015 21 4 21 145 26 ...

Page 190: ...Transmission 21 Dropbox 200 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 21 5 21 200 1 ...

Page 191: ...Contents Transmission 21 Dropbox 200 SERVICE Dropbox Remove 3 Disassemble 4 Assemble 5 Install 6 47866583_ 02 12 2015 21 5 21 200 2 ...

Page 192: ...ee Drive shaft Remove 23 314 for the drive shaft removal 2 Detach the hand lever vertical rod 1 from the drop box control lever 3 Remove the mounting bolts 2 and remove the drop box assembly NOTE Drain the oil from the drop box by removing the drain plug on the drop box 20097721 1 47866583_ 02 12 2015 21 5 21 200 3 ...

Page 193: ...seal disc 7 Shaft seal 8 Retaining ring 9 Output shaft 10 with bearing 11 and dust ex cluder 12 NOTE Drill a 1 8 inch hole on each side of the dust seal 7 and shaft seal 8 and insert sheet metal screws into the holes to pull the parts from the case bore 5 Remove the output shaft gear 13 and splined coupler 14 from the case 200900126 2 6 To remove shift lever Unscrew the plug 15 with sealing washer...

Page 194: ...the rear bearing Seat shaft fully into rear bearing 7 Install the dust excluder 12 and the front bearing 13 onto the output shaft 8 Install retaining ring 14 into the groove in the drop box 9 Install shaft seal 15 and dust seal disc 16 into the drop box 10 Install retaining ring 17 onto the output shaft 11 Slide the idler gear shaft 18 into the front of the trans fer box and slide the spacer 19 ne...

Page 195: ...ead of gasket eliminator 518 onto the mount ing surface of the transfer box 3 Install transfer box assembly onto the tractor using eight M10 x 30 2 mounting bolts 4 Torque bolts to 49 0 62 8 N m 36 1 46 3 lb ft 5 Attach the vertical hand lever rod 3 onto the drop box lever 6 Refill transmission with oil 47866583_ 02 12 2015 21 5 21 200 6 ...

Page 196: ...Index Transmission 21 Dropbox 200 Dropbox Assemble 5 Dropbox Disassemble 4 Dropbox Install 6 Dropbox Remove 3 47866583_ 02 12 2015 21 5 21 200 7 ...

Page 197: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 198: ...SERVICE MANUAL Four Wheel Drive 4WD system Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 23 ...

Page 199: ...Contents Four Wheel Drive 4WD system 23 23 314 Drive shaft 23 1 47866583_ 02 12 2015 23 ...

Page 200: ...Four Wheel Drive 4WD system 23 Drive shaft 314 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 23 1 23 314 1 ...

Page 201: ...Contents Four Wheel Drive 4WD system 23 Drive shaft 314 SERVICE Drive shaft Remove 3 Install 4 47866583_ 02 12 2015 23 1 23 314 2 ...

Page 202: ...tions GNIL14TR00823AA 1 2 Unseat the retaining rings 1 and 2 Slide the splined couplers 3 and 4 toward the center mounting bracket of the 4WD shaft GNIL15TR01128FA 2 3 Remove the two mounting bolts 1 from center mount ing bracket of the 4WD shaft 4 Remove the 4WD shaft 2 GNIL15TR01129AA 3 5 Inspect splines of shaft coupler and condition of bore of center support housing for wear or damage 47866583...

Page 203: ...olts 1 on the center mounting bracket of the Four Wheel Drive 4WD shaft GNIL15TR01129AA 2 2 Engage the spline coupler 2 figure 1 on the Power Take Off PTO shaft of the front axle and the 4WD shaft 3 Push the 4WD shaft 1 toward the front axle GNIL15TR01130AA 3 47866583_ 02 12 2015 23 1 23 314 4 ...

Page 204: ...drop box 7 Measure the gap 2 on the 4WD shaft between retain ing ring groove and sleeve face GNIL15TR01131AA 5 8 Slide the spline coupler 1 away from the drop box GNIL15TR01130AA 6 9 Insert suitable shim or combination of shims 9 figure 1 on the drop box PTO shaft to make up for the gap Maintain a free play of 0 3 mm 10 Slide the spline coupler toward the drop box and seat the retaining ring 3 fig...

Page 205: ...Four Wheel Drive 4WD system Drive shaft 11 Fit the drive shaft guard and tighten the bolts 1 on both the ends GNIL14TR00823AA 7 47866583_ 02 12 2015 23 1 23 314 6 ...

Page 206: ...Index Four Wheel Drive 4WD system 23 Drive shaft 314 Drive shaft Install 4 Drive shaft Remove 3 47866583_ 02 12 2015 23 1 23 314 7 ...

Page 207: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 208: ...SERVICE MANUAL Front axle system Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 25 ...

Page 209: ...m 25 25 100 Powered front axle 25 1 25 102 Front bevel gear set and differential 25 2 25 108 Final drive hub steering knuckles and shafts 25 3 25 310 Final drives 25 4 25 400 Non powered front axle 25 5 47866583_ 02 12 2015 25 ...

Page 210: ...Front axle system 25 Powered front axle 100 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 25 1 25 100 1 ...

Page 211: ... axle General specification 3 Torque 5 Special tools 6 FUNCTIONAL DATA Four Wheel Drive 4WD axle Overview 8 Sectional view 9 SERVICE Four Wheel Drive 4WD axle Remove 12 Remove 15 Install 18 Disassemble 19 Inspect 25 Assemble 26 Adjust 27 Toe in adjust 30 47866583_ 02 12 2015 25 1 25 100 2 ...

Page 212: ...mm 0 1457 in Clearance between sides of planet and side pinion teeth 0 15 mm 0 006 in Thickness of planet pinion thrust washers 1 470 mm 0 058 in 1 530 mm 0 060 in Thickness of side gear thrust washers 1 50 mm 0 059 in to 1 60 mm 0 063 in Diameter of cross pin for planet pinions 21 939 mm 0 8637 in 21 960 mm 0 8646 in Side diameter cross pin bore diameter 22 040 mm 0 8677 in to 22 061 mm 0 8685 in...

Page 213: ...mm 3 8992 in 99 72 mm 3 9260 in Rear bushing fitted 99 146 mm 3 9034 in 99 221 mm 3 9063 in Spigot fitted clearance in bushing 0 074 mm 0 0029 in 0 181 mm 0 0071 in Axle front and rear thrust washer thickness 4 95 mm 0 1949 in 5 00 mm 0 1969 in Turning radius Turning radius with brakes 4200 0 mm 165 4 in Turning radius without brakes 4850 0 mm 190 9 in Turnaround diameter Turnaround diameter with ...

Page 214: ...b ft Steering knuckle bolt C5 M10 x 1 25 64 N m 47 lb ft Wheel hub bearings lock nut C6 M45 x 1 5 392 N m 289 lb ft Bolt planetary final drive housing C7 M10 x 1 25 64 N m 47 lb ft Bolt wheel disc to hub C8 M16 x 1 5 193 N m 142 lb ft Nut for rim to disc securing bolt M16 x 1 5 193 N m 142 lb ft Front axle front and rear pivot support bolt C9 M18 x 1 5 280 N m 207 lb ft Differential cage support c...

Page 215: ...Front axle system Powered front axle Four Wheel Drive 4WD axle Special tools GNIL14TR04346HA 1 47866583_ 02 12 2015 25 1 25 100 6 ...

Page 216: ...Front axle system Powered front axle GNIL14TR04347HA 2 47866583_ 02 12 2015 25 1 25 100 7 ...

Page 217: ...e Front to rear axle ratio NOTE On tractors equipped with FWD Front Wheel Drive the front to rear axle ratio is critical and must be main tained for safe and efficient use of the tractor This ratio applies to all available tire options Following is a list of problems that may occur if the front to rear axle ratio is not maintained Engine will lug down or stall when operating on hard surfaces The f...

Page 218: ... Rear bushing S5 Sleeve position shim 25 Rear axle pivot support C9 Axle pivot support bolt 26 Retaining rings C10 Differential bearing cap bolt 27 Front splined sleeve C11 Bolt securing front axle support to engine 28 Retaining rings 20 Front axle pivot support 29 Drive shaft guard 21 Front bushing 30 Drive shaft 22 Front thrust washer 47866583_ 02 12 2015 25 1 25 100 9 ...

Page 219: ... gear washers C1 Bevel pinion bearing lock ring 7 Differential pinion washers C2 Differential carrier bolt 8 Differential pinion journal bolt C3 Ring gear bolt 60 Side gear Gd Gs Right hand side and left hand side differential bearing lock ring 61 Side gear 1 Bevel pinion 62 Differential pinion 2 Seal 63 Differential pinion journal 3 Bevel pinion bearing spacer 47866583_ 02 12 2015 25 1 25 100 10 ...

Page 220: ...hims 12 Seal C4 King pin bearing bolt 13 Seal C5 Steering knuckle bolt 14 Axle shaft bushing C6 Wheel hub bearing lock ring 15 Spacer C7 Final drive housing bolt 16 Thrust washers C8 Wheel hub bolt 17 Planet wheel journals 9 Bearing carrier bolt 18 Planet wheel shims 10 Seal 19 Sun gear 47866583_ 02 12 2015 25 1 25 100 11 ...

Page 221: ... comply could result in death or serious injury W0398A NOTE The front axle assembly can be removed from the tractor either with or without previously removing the drive shaft The description below refers to removal of the front axle with the drive shaft installed on the tractor 1 Disconnect the negative battery terminal 1 GNIL14TR00784AA 1 2 Remove the front weights 1 GNIL14TR00756AA 2 3 Remove th...

Page 222: ...front axle input shaft and drop box output shaft by sliding the two couplers onto the drive shaft GNIL14TR00859AA 5 7 Attach nylon slings around the front axle and attach them to a hoist 8 Lift the tractor with the hoist and place a stand under the lower portion of the front axle GNIL14TR04361AA 6 9 Remove the power steering hoses 1 from the power steering tubes GNIL14TR04362AB 7 47866583_ 02 12 2...

Page 223: ...A 8 11 Remove the front axle rear support retaining bolts 1 GNIL14TR04364AB 9 12 Remove the front axle front support retaining bolts 1 13 Using a hoist and nylon cables one for each side detach the front axle from the tractor GNIL14TR04365AB 10 47866583_ 02 12 2015 25 1 25 100 14 ...

Page 224: ...could result in death or serious injury W0398A Proceed as follows NOTE The front axle assembly can be removed from the tractor either with or without previously removing the drive shaft The description below refers to removal of the front axle with the drive shaft installed on the tractor 1 Disconnect the negative battery lead 1 GNIL14TR00784AA 1 2 remove the front weights 1 GNIL14TR00829AA 2 3 Re...

Page 225: ...front axle input shaft and drop box output shaft by sliding the two couplers onto the drive shaft GNIL14TR00859AA 5 7 Attach nylon slings around the front axle and attach them to a hoist 8 Lift the tractor with the hoist and place a stand under the lower portion of the front axle GNIL14TR04361AA 6 9 Remove the power steering hoses 1 from the power steering tubes GNIL14TR04362AB 7 47866583_ 02 12 2...

Page 226: ... 8 11 Remove the front axle rear support retaining bolts 1 GNIL14TR04364AB 9 12 1 Remove the front axle front support retaining bolts 1 2 Using a hoist and nylon cables one for each side detach the front axle from the tractor GNIL14TR04365AB 10 47866583_ 02 12 2015 25 1 25 100 17 ...

Page 227: ...all the axle and bolt the front and rear supports in position Reconnect the power steering hoses Install the front wheels Raise the front of the tractor using the hoist Remove the fixed stand Detach the nylon cables Reconnect the drive shaft and install the drive shaft guard Attach a nylon cable to the front weights lift install to the tractor and secure with the locking screws Reconnect the negat...

Page 228: ...safety footwear Failure to comply could result in death or seri ous injury W0208A GNIL14TR04367AA 1 1 Remove plug 1 and drain the oil from the axle cas ing GNIL14TR04368AB 2 2 To drain the final drive oil remove plug 1 on the left hand final drive casing 3 Repeat the same operation on the right hand side casing GNIL14TR04369AB 3 4 Remove the rear support 1 off the front axle 5 Remove the front sup...

Page 229: ... bottom of the cylinder rod pivot pin 1 9 Remove the pin retaining bolt 2 from the pin Re move the pins and detach the cylinder GNIL14TR04373AB 7 10 Unscrew the retaining bolts off the left hand final drive casing cover 1 11 Screw in the two M10 x 100 dowels tool no 380002813 2 12 Using a slide hammer puller screwed into the oil drain plug 13 Detach the cover 1 from the casing GNIL14TR04374AB 8 47...

Page 230: ...r 2 GNIL14TR04375AB 9 16 Remove the staking 1 on the wheel hub bearing lock ring 2 GNIL14TR04377AB 10 17 Remove the wheel hub bearing lock ring using tool no 380000295 1 GNIL14TR04378AB 11 18 Remove the wheel hub 1 with the ring gear 2 GNIL14TR04379AB 12 47866583_ 02 12 2015 25 1 25 100 21 ...

Page 231: ...etaining bolts of the upper pivot pin 22 Remove the upper pivot pin 1 23 Remove the stub axle housing 2 GNIL14TR04381AB 14 24 Remove the retaining bolt 1 of the axle shaft 2 GNIL14TR04382AB 15 25 Using a pry bar pull the axle shaft out of the casing 26 To disassemble the right hand final drive unit re peat the above steps Invalid Reference to Invalid Reference GNIL14TR04383AA 16 47866583_ 02 12 20...

Page 232: ... 2 to the support and take up the weight with the hoist 31 Remove the bevel drive differential support 3 from the axle casing GNIL14TR04384AB 17 32 Remove the two bolts 1 from the two ring gear differential support caps 2 33 Remove the crown wheel differential assembly from the housing GNIL14TR04385AB 18 34 Remove the snap ring 1 from the splined shaft 2 GNIL14TR04386AB 19 35 Straighten the lockin...

Page 233: ...the splined shaft detent ball 1 GNIL14TR04389AB 22 38 Remove the bevel drive pinion shaft 1 from the rear of the casing and remove the spacer the adjust ment shims and the bearing NOTE Observe the quantity and the size of the shims re moved from the pinion shaft GNIL14TR04390AB 23 39 Using a screwdriver remove the dust seal seal ring 1 and rear bearing GNIL14TR04391AB 24 47866583_ 02 12 2015 25 1 ...

Page 234: ...he gears for excess wear or damage Replace as necessary 3 Check all the bearings for wear or roughness Rotate the bearings by hand and replace if necessary 4 Inspect the axle shafts and pinion shaft for wear or damage Replace if necessary 5 Inspect the front axle housing for any damage Replace if necessary 47866583_ 02 12 2015 25 1 25 100 25 ...

Page 235: ...upport caps and tighten the relative bolts Install the bevel drive differential housing on the front axle casing Install the axle shaft and relative bolt Install the stub axle the adjustment shims the upper and lower pivot pins Install the wheel hub the ring gear of the final drive unit and the lock ring and tighten to the prescribed torque value while simultaneously turning the wheel hub to ensur...

Page 236: ...sing GNIL14TR04392AA 1 2 Insert the outer bearing rings in the differential housing Install the differential support caps Torque the bolts to 59 N m 44 lb ft then loosen and re tighten to a torque of 20 N m 15 lb ft GNIL14TR04399AB 2 3 With the bearings lubricated rotate the ring gear and at the same time tighten the threaded adjustment ring using wrench tool no 380000252 A to a torque of 39 59 N ...

Page 237: ...in GNIL14TR04393AB 5 7 Using a wrench tool number 380000252 A turn the threaded adjustment ring and check using torque wrench 2 that the combined rolling resistance torque of the ring gear and pinion bearings is A2 A1 1 0 N m 0 74 lb ft to 1 5 N m 1 11 lb ft where A2 combined ring gear pinion rolling resistance torque A1 rolling resistance torque of pinion only as mea sured previously 1 0 N m 0 74...

Page 238: ...nt axle system Powered front axle 11 Gasket eliminator LOCTITE 518 application diagram for assembly of bevel drive unit and epicyclic final drive unit GNIL14TR04394AB 7 47866583_ 02 12 2015 25 1 25 100 29 ...

Page 239: ...ctor forward to turn both front wheels through 180 The chalk marks will now be measure between the rear inside edges of the wheel rims at the height of the wheel hub centers Now measure the distance 2 checking that this new measurement is equal to or greater than the distance 1 by a maximum or 6 mm 0 24 in The rotation of the wheels through 180 is necessary to eliminate the effect of wear misalign...

Page 240: ...l specification 3 Four Wheel Drive 4WD axle Inspect 25 Four Wheel Drive 4WD axle Install 18 Four Wheel Drive 4WD axle Overview 8 Four Wheel Drive 4WD axle Remove 12 Four Wheel Drive 4WD axle Remove 15 Four Wheel Drive 4WD axle Sectional view 9 Four Wheel Drive 4WD axle Special tools 6 Four Wheel Drive 4WD axle Toe in adjust 30 Four Wheel Drive 4WD axle Torque 5 47866583_ 02 12 2015 25 1 25 100 31 ...

Page 241: ...47866583_ 02 12 2015 25 1 25 100 32 ...

Page 242: ...Front axle system 25 Front bevel gear set and differential 102 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 25 2 25 102 1 ...

Page 243: ...Contents Front axle system 25 Front bevel gear set and differential 102 SERVICE Differential Adjust 4WD Front axle 3 47866583_ 02 12 2015 25 2 25 102 2 ...

Page 244: ...planet pinions complete with thrust washers and pins and screw the pin retaining bolts in by a few turns to hold the pins in place 4 Position a dial gauge on the differential housing 5 Move the left hand side gear to bring it into full contact with the planet pinion and then push it up against the differential housing reading the end play GL on the dial gauge 20097712 1 6 Repeat the above operatio...

Page 245: ...heck that the end float of the left and right hand side gears is approximately 0 25 mm 0 010 in 20097714 3 Differential side gear shim sizes Available shim sizes mm inches 1 0 mm 0 039 in 1 6 mm 0 063 in 1 1 mm 0 043 in 1 7 mm 0 067 in 1 2 mm 0 047 in 1 8 mm 0 071 in 1 3 mm 0 051 in 1 9 mm 0 075 in 1 4 mm 0 055 in 2 0 mm 0 039 in 1 5 mm 0 059 in 47866583_ 02 12 2015 25 2 25 102 4 ...

Page 246: ...Index Front axle system 25 Front bevel gear set and differential 102 Differential Adjust 4WD Front axle 3 47866583_ 02 12 2015 25 2 25 102 5 ...

Page 247: ...47866583_ 02 12 2015 25 2 25 102 6 ...

Page 248: ...Front axle system 25 Final drive hub steering knuckles and shafts 108 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 25 3 25 108 1 ...

Page 249: ...ts Front axle system 25 Final drive hub steering knuckles and shafts 108 SERVICE Steering knuckle and king pin Remove 3 Adjust Stub Axle 4 Wheel hub Adjust 4WD Front Axle 6 47866583_ 02 12 2015 25 3 25 108 2 ...

Page 250: ... 1 using tool number 380000265 3 Install the plate 2 from the tool and retain it to the three bolts with nuts 3 4 Install the central tie bolt 4 screwing it fully into the grease nipple bore on the pin 5 5 Screw in the nut 6 to drive the pin out of its bore GNIL14TR04428AB 1 6 Using extractor tool tool number 380000234 1 re move the steering knuckle bearings GNIL14TR04429AB 2 NOTE Re install the s...

Page 251: ...14TR04412AB 1 2 Install the lower cover without adjustment plate lubri cate the three retaining bolts with oil 3 Gradually tighten the lower cover bolts in sequence while simultaneously rotating the casing to allow the excess grease to escape GNIL14TR04413AA 2 4 Using a torque wrench tool number 380000235 1 check that the torque required to rotate the casing is 2 9 N m 25 7 lb in without consideri...

Page 252: ...n check that the torque necessary to rotate the casing is 2 9 N m 25 7 lb in 7 8 N m 69 lb in without considering the initial peak torque 9 If the torque value measured is greater than the pre scribed value increase the thickness of the shims if the measured value is less than the prescribed value reduce the thickness of the shims 10 Install the grease nipples in the upper and lower cov ers and gr...

Page 253: ...gressively tighten the lock ring to 147 196 N m 108 145 lb ft While tighten ing the lock ring rotate the hub to seat the bearings Fully loosen the lock ring and retighten to 392 N m 289 lb ft while rotating hub Secure the lock ring by bending over a lock washer tab if necessary further tighten the lock ring to align a slot with the tab Turn the hub by hand to check for excessive play or binding GN...

Page 254: ...e system 25 Final drive hub steering knuckles and shafts 108 Steering knuckle and king pin Adjust Stub Axle 4 Steering knuckle and king pin Remove 3 Wheel hub Adjust 4WD Front Axle 6 47866583_ 02 12 2015 25 3 25 108 7 ...

Page 255: ...47866583_ 02 12 2015 25 3 25 108 8 ...

Page 256: ...Front axle system 25 Final drives 310 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 25 4 25 310 1 ...

Page 257: ...Contents Front axle system 25 Final drives 310 SERVICE Final drive driving pinion Preload 4WD Front Axle 3 Adjust 4WD Front Axle 5 47866583_ 02 12 2015 25 4 25 310 2 ...

Page 258: ...4 in thick spacer between tool number 380000248 1 and the bearing 2 GNIL14TR04419AB 1 2 Using a micrometer measure distance H1 be tween the upper surface and the pin of tool number 380000248 1 3 Disassemble the above parts lubricate the bearings with oil and then re assemble the parts excluding the bearing spacer in the bevel drive differential housing complete with outer bearing races held in pla...

Page 259: ... gear and front bearing NOTE On completing the adjustment do not remove the adjustment tool from the bevel drive differential housing leave in place for adjustment of the drive pinion position GNIL14TR04422AB 4 Available shim sizes 0 5 mm 0 020 in 2 7 mm 0 106 in 2 5 mm 0 098 in 2 8 mm 0 110 in 2 6 mm 0 102 in 2 9 mm 0 114 in 47866583_ 02 12 2015 25 4 25 310 4 ...

Page 260: ... ring gear axis and the large diameter base of the pinion H5 H4 C where H4 95 mm 3 74 in nominal distance between the ring gear axis and the large diameter base of the pinion C correction value stamped on pinion preceded by a or sign if other than 0 to be added to or subtracted from the nominal distance H4 according to the sign 5 The thickness of the adjustment shim will be given by Shim H3 H5 whe...

Page 261: ...y GNIL14TR04430AB 4 13 With a torque wrench 1 on the pinion lock tool tool number 380000257 2 check that the pinion rolling torque without oil seal and relative dust seal ring is 0 N m 0 lb in 0 2 N m 1 8 lb in If the rolling torque is less than the prescribed value install a thinner adjustment shim shown in Figure 2 if the torque is greater than the prescribed value install a thicker adjustment s...

Page 262: ...Index Front axle system 25 Final drives 310 Final drive driving pinion Adjust 4WD Front Axle 5 Final drive driving pinion Preload 4WD Front Axle 3 47866583_ 02 12 2015 25 4 25 310 7 ...

Page 263: ...47866583_ 02 12 2015 25 4 25 310 8 ...

Page 264: ...Front axle system 25 Non powered front axle 400 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 25 5 25 400 1 ...

Page 265: ...Sealing 4 FUNCTIONAL DATA Non powered front axle Overview 5 Sectional view 6 SERVICE Non powered front axle Remove 8 Install 10 Front axle Remove Spindle Assembly 11 Overhaul Spindle Assembly 13 Install Spindle assembly 14 Axle wheel hub Remove 15 Install 17 DIAGNOSTIC Non powered front axle Troubleshooting 18 47866583_ 02 12 2015 25 5 25 400 2 ...

Page 266: ...in to bush clearance 0 060 0 173 mm 0 002 0 007 in 2WD Dished In 7 50 16 AC 1424 0 mm 56 1 in BD 1524 0 mm 60 0 in CE 1624 0 mm 63 9 in DF 1724 0 mm 67 9 in EG 1824 0 mm 71 8 in FH 1924 0 mm 75 7 in 2WD Dished Out AC 1472 0 mm 58 0 in BD 1572 0 mm 61 9 in CE 1672 0 mm 65 8 in DF 1772 0 mm 69 8 in EG 1872 0 mm 73 7 in FH 1972 0 mm 77 6 in Non powered front axle Torque Description Thread size Torque...

Page 267: ...Special tools Tool description Tool number Slide hammer for centre pin 380001545 Adapter for slide hammer 290793 Non powered front axle Sealing Operation description Specification Front wheel hub sleeve LOCTITE 638 King pin thrust washer LOCTITE 638 47866583_ 02 12 2015 25 5 25 400 4 ...

Page 268: ...k width adjustment purpose Adjustment of the front wheel track width is affected by extending or retracting both ends of the axle equally The centre beam is attached to the front axle carrier by means of a single pivot which allows oscillation on both sides The front axle is controlled by mechanical steering through swivel pin control lever The two swivel pins are connected by telescopic track con...

Page 269: ...nt axle Non powered front axle Sectional view GNIL14TR04432FB 1 Front axle support 1 Grease fitting 4 Thrust washers 2 Axle centre beam 5 Axle pivot pin 3 Axle pivot pin bushings 6 Front axle carrier 47866583_ 02 12 2015 25 5 25 400 6 ...

Page 270: ... 11 Grease nipple 2 Oil seal 12 Bearing 3 Bush upper 13 Thrust washer 4 Bush lower 14 Castle nut 5 Thrust washer 15 Split pin 6 Seal 16 Dust cover 7 Dust cover 17 O ring 8 Bush sleeve 18 Thrust washer pin 9 Seal 19 Grease nipple 10 Bearing 20 King pin 47866583_ 02 12 2015 25 5 25 400 7 ...

Page 271: ...s injury D0076A Remove the front axle assembly from the tractor as fol lows 1 Open and raise front hood 2 Disconnect the negative cable from the battery and in sulate 3 Safely block rear wheels 4 Remove front weights and weight support where fitted 5 Jack up front tractor and place a stationary stand 1 under the sump GNIL14TR04434AB 1 6 Loosen retaining bolts 1 and remove the front wheels GNIL14TR...

Page 272: ...R04437AB 4 11 Using a slide puller special tool number 292927 with tool no 380001545 withdraw the pivot pin 1 10 Recover thrust washers and shims provided be tween axle carrier and centre beam 11 Remove front axle from tractor using a hoist GNIL14TR04438AB 5 47866583_ 02 12 2015 25 5 25 400 9 ...

Page 273: ...ON Pinch hazard Always use suitable tools to align mating parts DO NOT use your hand or fingers Failure to comply could result in minor or mod erate injury C0044A 2 Check the pivot pin play It should not exceed 0 25 mm 0 01 in If play is more add shims between axle car rier and centre beam 3 Check for correct toe in setting See front wheel set ting tests for details 4 Tighten all fasteners to corr...

Page 274: ...ous injury W0208A Swivel pins can be removed and overhauled with the front axle on the tractor proceed as follows for each wheel 1 Safely block rear wheels 2 Jack up front tractor and place a stationary stand 1 under the sump 3 Loosen retaining bolts and remove front wheels GNIL14TR04449AB 1 4 Remove swivel pin control lever retaining bolt 1 5 Slide out the control lever 2 from the spindle assem b...

Page 275: ...Front axle system Non powered front axle 7 Remove the axle outer section 1 attaching bolts GNIL14TR04452AB 4 8 Remove the axle outer section 1 GNIL14TR04453AB 5 47866583_ 02 12 2015 25 5 25 400 12 ...

Page 276: ... thrust washer 3 Check the swivel bearing bushes for wear See spec ifications in Non powered front axle General spec ification 25 400 If bushes require replacement re move the bushes using suitable tool 4 Using a suitable drift install new bushings on the axle outer section 5 Check the swivel pin for wear If required replace new spindle 6 Ream the new bushings to suit the swivel pin GNIL14TR04455A...

Page 277: ...le assembly Reinstall the spindle assembly to the front axle following the disassembly procedure in reverse NOTE Make sure that the slot 1 in the thrust washer fits on the notch provided on the axle outer section GNIL14TR04456AB 1 47866583_ 02 12 2015 25 5 25 400 14 ...

Page 278: ...afety footwear Failure to comply could result in death or serious injury W0208A Wheel hubs can be removed with the front axle on the tractor Proceed as follows for each hub 1 Safely block rear wheels 2 Jack up front tractor and place a stationary stand 1 under the sump 3 Loosen retaining bolts and remove front wheels GNIL14TR04439AB 1 4 Remove wheel hub bearing grease cup 1 GNIL14TR04440AB 2 5 Rem...

Page 279: ...socket spanner loosen the wheel hub bear ing Adjust castle nut GNIL14TR04442AA 4 7 Remove wheel hub 2 and recover bearing 1 and 3 GNIL14TR04443AB 5 8 Remove seal 1 and nyloc ring 2 using suitable tool GNIL14TR04444AB 6 47866583_ 02 12 2015 25 5 25 400 16 ...

Page 280: ...ket spanner 1 tighten the castle nut while turning the wheel hub 1 to set tle the bearing Tighten the nut until wheel hub gets slightly tight to rotate 5 Loosen the castle nut and torque it again to 9 8 N m 7 2 lb ft continuing to turn the wheel hub GNIL14TR04446AA 2 6 Insert split pin 1 GNIL14TR04447AB 3 7 Reassemble the wheel hub dust cap 1 NOTE Check the O ring provided on the dust cap for any ...

Page 281: ...nflate tyres to correct pressure refer to val ues suggested in the operator s manual Always comply with values specified by the tire manufacture Wrong front wheel toe in Adjust toe in see the procedure explained in this section under adjustment Poor tractor stability Wrong inflation pressure Inflate tyres to correct pressure 47866583_ 02 12 2015 25 5 25 400 18 ...

Page 282: ... Remove Spindle Assembly 11 Non powered front axle General specification 3 Non powered front axle Install 10 Non powered front axle Overview 5 Non powered front axle Remove 8 Non powered front axle Sealing 4 Non powered front axle Sectional view 6 Non powered front axle Special tools 4 Non powered front axle Torque 3 Non powered front axle Troubleshooting 18 47866583_ 02 12 2015 25 5 25 400 19 ...

Page 283: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 284: ...SERVICE MANUAL Rear axle system Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 27 ...

Page 285: ...Contents Rear axle system 27 27 100 Powered rear axle 27 1 27 106 Rear bevel gear set and differential 27 2 27 120 Planetary and final drives 27 3 47866583_ 02 12 2015 27 ...

Page 286: ...Rear axle system 27 Powered rear axle 100 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 27 1 27 100 1 ...

Page 287: ...Contents Rear axle system 27 Powered rear axle 100 FUNCTIONAL DATA Powered rear axle Overview 3 47866583_ 02 12 2015 27 1 27 100 2 ...

Page 288: ...utch type and operated by foot pedal located below operator s seat at right hand side The planetary reduction gear set is controlled by the bevel pinion and crown wheel output half shaft which also controls the brakes Planetary helps in improving traction and increasing brakes life It also gives more ground clearance and it is sealed against water and dust In this cascade arrangement half axle is ...

Page 289: ...Index Rear axle system 27 Powered rear axle 100 Powered rear axle Overview 3 47866583_ 02 12 2015 27 1 27 100 4 ...

Page 290: ...Rear axle system 27 Rear bevel gear set and differential 106 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 27 2 27 106 1 ...

Page 291: ...pecial tools 4 Sealing 4 FUNCTIONAL DATA Rear bevel gear set and differential Sectional view 6 SERVICE Rear bevel gear set and differential Remove 7 Install 12 Differential Disassemble 14 Inspect 17 Assemble 18 Backlash 19 Bevel pinion Remove 21 Install 24 DIAGNOSTIC Rear bevel gear set and differential Troubleshooting 25 47866583_ 02 12 2015 27 2 27 106 2 ...

Page 292: ...h 0 100 mm 0 004 in 0 250 mm 0 010 in Differential gear pin diameter 21 960 mm 0 865 in 21 939 mm 0 864 in Bore diameter on differential gears for pin 22 098 mm 0 870 in 22 065 mm 0 869 in Bore diameter on differential case for pin 22 020 mm 0 867 in 22 000 mm 0 866 in Pin to differential gear clearance 0 159 mm 0 006 in 0 040 mm 0 002 in Pin to differential case clearance 0 082 mm 0 003 in 0 040 ...

Page 293: ... seal wheel side heavy duty 84261386 Set screw socket 6 000 mm 0 236 in 84261394 Yoke and spreader 291051 and 291052 Rear bevel gear set and differential Sealing Operation description Sealant specification Rear axle to transmission housing S1 LOCTITE 518 Lift housing to transmission housing S2 LOCTITE 518 Power Take Off PTO cover plate S3 LOCTITE 518 Crown wheel bolts S4 LOCTITE 243 47866583_ 02 1...

Page 294: ...Rear axle system Rear bevel gear set and differential GNIL14TR04240GB 1 47866583_ 02 12 2015 27 2 27 106 5 ...

Page 295: ...gear set and differential Sectional view Crown wheel and differential assembly GNIL14TR04241GB 1 1 Crown wheel 5 Power Take Off PTO shaft 2 Pinion shaft 6 Differential assembly 3 Input shaft 7 Brake 4 Power Take Off PTO input shaft 47866583_ 02 12 2015 27 2 27 106 6 ...

Page 296: ...final drive housing brake assembly and Power Take Off PTO assembly has to be removed Remove the rear axle housing as follows 1 Detach the negative cable 1 from the battery and in sulate GNIL14TR00784AA 1 2 Disconnect the electrical couplings 1 GNIL14TR00797AA 2 3 Detach electric connections 1 between left and right hand side fenders GNIL14TR04245AB 3 47866583_ 02 12 2015 27 2 27 106 7 ...

Page 297: ...ve operator seat from the hydraulic housing GNIL14TR04246AB 4 5 Disconnect hydraulic lines 1 on the hydraulic lift body GNIL14TR00798AA 5 6 Remove three point linkages from the tractor GNIL14TR00562AA 6 7 Loosen bolts securing foot rest to fender on both sides GNIL14TR00767AA 7 47866583_ 02 12 2015 27 2 27 106 8 ...

Page 298: ...of the tractor and place two suitable stands under transmission housing to raise the wheels off the ground 10 Drain oil from the transmission housing GNIL14TR00564AA 8 11 Remove both left and right hand side wheels GNIL14TR04252AA 9 12 Loosen the bolts and remove fenders from both sides GNIL14TR00790AA 10 47866583_ 02 12 2015 27 2 27 106 9 ...

Page 299: ... for the final drive housing on the other side 16 Remove the cover plate by removing Allen screw 1 and remove cover plate 2 Retrieve oil rings 2 num bers from the housing and cover plate respectively 17 Loosen the bolts securing hydraulic lift housing to transmission housing Lift the hydraulic lift assembly using suitable hoist and place it on a flat surfaced table 18 Remove Power Take Off PTO eng...

Page 300: ...r Take Off PTO cover bolts and pull out the cover along with Power Take Off PTO shaft and Power Take Off PTO input shaft assembly See Rear mechanical control Remove 31 101 GNIL14TR00742AA 14 20 Take out the differential assembly along with crown wheel GNIL14TR04258AB 15 47866583_ 02 12 2015 27 2 27 106 11 ...

Page 301: ...ial Install 27 106 Check seals and replace if damaged Before reassembling housings supports and covers thoroughly clean and degrease mating surfaces and apply a bead of liquid gasket of approx 2 000 mm 0 079 in of diameter following the patterns shown in the figure Tighten to correct torques Preload tapper roller bearings by adding and remov ing shims and set crown pinion backlash by following the...

Page 302: ...cal lift housing Check the backlash with the help of dial gauge Permissible backlash is 0 180 0 230 mm 0 007 0 009 in if it is less than tighten left hand side ring nut after slightly loosening right hand side ring nut If it is more than 0 180 0 230 mm 0 007 0 009 in then first loosen left hand side ring nut and then tighten right hand side ring nut 47866583_ 02 12 2015 27 2 27 106 13 ...

Page 303: ...nual including protective goggles gloves and safety footwear Failure to comply could result in death or serious injury W0208A With the assembly removed from the rear axle housing proceed as follows 1 Loosen the crown wheel attaching bolts 1 GNIL14TR04260AB 1 2 Detach the crown wheel 1 from the differential hous ing GNIL14TR04261AB 2 3 Loosen and remove all the bolts 1 from the casing GNIL14TR04262...

Page 304: ...ve the locking pin 1 locking the differential gear pivot pin GNIL14TR04264AB 5 6 Remove the pivot pin 1 and withdraw the side gears from the differential housing along with trust washer GNIL14TR04265AB 6 NOTE Four differential gear 1 and side gear 2 have thrust washers with same thickness GNIL14TR04266AB 7 47866583_ 02 12 2015 27 2 27 106 15 ...

Page 305: ... differential 7 Using suitable puller special tool number 291051 and 291052 remove the bearings from both the sides GNIL14TR04267AA 8 8 Remove the differential lock clutch from the housing GNIL14TR04268AB 9 47866583_ 02 12 2015 27 2 27 106 16 ...

Page 306: ...ar axle system Rear bevel gear set and differential Differential Inspect Inspect all gears thrust washers bearings for any kind of damages or wear Replace if necessary 47866583_ 02 12 2015 27 2 27 106 17 ...

Page 307: ...l the components of the differential assem bly observing the following Re assembly follows the disassembly procedure in reverse See Differential Disassemble 27 106 Set crown or pinion backlash and total preload set ting See Differential Backlash 27 106 Use suitable tools to fit bearings Tighten to correct torques Use thread sealant LOCTITE 243 on crown wheel bolts Set sun star backlash to 0 180 0 ...

Page 308: ...d side gear end float Gd Right hand side gear end float H1 and H2 Dimensions measured on left hand side or right hand side gears Normal differential pinion and side gear backlash is 0 15 mm 0 01 in Note that the average ratio normal backlash to the equivalent side gear end float is 1 to 1 7 Side gear end float corresponding to normal backlash will be 0 15 x 1 8 0 250 mm 0 010 in Consequently the s...

Page 309: ...l gauge and magnetic stand as shown in figure Backlash to keep in between 0 180 0 230 mm 0 007 0 009 in GNIL14TR04273AA 5 4 Measure the torque using a spring balance and chord wound around the sleeve of low gear it should be be tween 4 00 5 50 kgm 28 93 39 78 ftlbs GNIL14TR04274AA 6 5 Fit the lock plate 1 back on bearing support ap ply thread lock sealant LOCTITE 243 to the Allen screws GNIL14TR04...

Page 310: ...y to remove the transmission housing from the tractor following the procedure described under transmission assembly re moval installation Also it is required to remove Power Take Off PTO cover and related components 1 Remove the driven shaft drive shaft and range shaft before dismantling pinion shaft GNIL14TR04069AA 1 2 1 To remove the crown wheel loosen set screws 1 from the cover plate 2 Remove ...

Page 311: ...tool special tool 1 number 84261392 GNIL14TR04073AB 5 6 Remove the pinion shaft lock nut using special tool number 84261389 GNIL14TR04074AB 6 7 Withdraw pinion shaft from the differential housing and retrieve low gear sleeve coupling etc from the pinion shaft NOTE Keep deep cut of hub towards pinion check nut side GNIL14TR04075AA 7 47866583_ 02 12 2015 27 2 27 106 22 ...

Page 312: ...al 8 Remove the circlip lock of the Gama Basasa bearing to remove bearing cone 1 from the housing GNIL14TR04076AB 8 9 Remove bearing from the pinion shaft using special tool number 291051 and 291052 GNIL14TR04077AB 9 47866583_ 02 12 2015 27 2 27 106 23 ...

Page 313: ...lso big spacer cut towards similarly NOTE Keep deep portion of low gear hub towards pinion check nut side After fitment check low gear it should rotate free GNIL14TR04080AA 3 4 After fitting pinion tighten pinion check nut at 28 kgm 203 ftlbs and check pinion bearing preload by wrap ping a cord around low gear hub with the help or spring balance it should be 2 5 3 0 kgm 18 1 21 7 ftlbs NOTE If rec...

Page 314: ...ng and replace damaged parts Noisy rear axle with tractor under load and upon release 1 Excess bevel pinion to ring gear back lash Remove rear axle housing and adjust bevel pinion and ring gear bearings correctly 2 Fault or defective inner components Remove rear axle housing replace worn parts and adjust differential gear backlash correctly Noisy rear axle with overheating 1 Insufficient pinion an...

Page 315: ...r set and differential General specification 3 Rear bevel gear set and differential Install 12 Rear bevel gear set and differential Remove 7 Rear bevel gear set and differential Sealing 4 Rear bevel gear set and differential Sectional view 6 Rear bevel gear set and differential Special tools 4 Rear bevel gear set and differential Torque 3 Rear bevel gear set and differential Troubleshooting 25 478...

Page 316: ...Rear axle system 27 Planetary and final drives 120 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 27 3 27 120 1 ...

Page 317: ...0 TECHNICAL DATA Planetary and final drives General specification 3 FUNCTIONAL DATA Final drive housing Sectional view 4 SERVICE Final drive housing Disassemble 5 Assemble 12 DIAGNOSTIC Final drive housing Troubleshooting 13 47866583_ 02 12 2015 27 3 27 120 2 ...

Page 318: ...Rear axle system Planetary and final drives Planetary and final drives General specification Type Epicyclic Reduction ratio 6 550 mm 0 258 in 47866583_ 02 12 2015 27 3 27 120 3 ...

Page 319: ...Rear axle system Planetary and final drives Final drive housing Sectional view GNIL14TR04242FB 1 Final drive 1 Trumpet housing 3 Planet gear 2 Rear wheel shaft 47866583_ 02 12 2015 27 3 27 120 4 ...

Page 320: ...c tive Equipment PPE as indicated in this manual including protective goggles gloves and safety footwear Failure to comply could result in death or serious injury W0208A 1 Remove the pin 1 and disconnect the brake linkage GNIL14TR00789AA 1 2 Loosen the bolts and remove the rear wheel GNIL14TR00866AA 2 3 Loosen the bolts and remove fender GNIL14TR00790AA 3 47866583_ 02 12 2015 27 3 27 120 5 ...

Page 321: ...00864AA 4 5 Remove the ROPS Roll Over Protective Structure NOTE Use a suitable hoist GNIL14TR00865AA 5 6 1 Wrap chain around final drive housing and loosen bolts 1 2 Remove the final drive housing GNIL14TR04276AB 6 7 Place the trumpet housing assembly on plane surface GNIL14TR04336AA 7 47866583_ 02 12 2015 27 3 27 120 6 ...

Page 322: ...move the linkage 1 GNIL14TR00792AA 8 9 Remove the nut and spring Remove the circlip GNIL14TR00791AA 9 10 Remove brake disc 1 and shaft 2 GNIL14TR04277AB 10 11 Remove the brake actuator assembly 1 GNIL14TR04278AB 11 47866583_ 02 12 2015 27 3 27 120 7 ...

Page 323: ...isc GNIL14TR00779AA 12 13 Remove intermediate plate and third brake disc GNIL14TR00780AA 13 14 Remove dual brake support 1 as shown GNIL14TR04279AB 14 15 Remove the set screw 1 holding the cover for road wheel shaft GNIL14TR04280AB 15 47866583_ 02 12 2015 27 3 27 120 8 ...

Page 324: ...nal drive GNIL14TR04281AB 16 17 Remove all three planet gears along with needle bear ings GNIL14TR04282AB 17 18 Remove the circlip lock 1 of planet carrier sub as sembly GNIL14TR04283AB 18 19 Remove the spacer and shims 1 GNIL14TR04284AB 19 47866583_ 02 12 2015 27 3 27 120 9 ...

Page 325: ... gear spacers and needle bearings for damage replace if found worn out GNIL14TR04286AA 21 22 Hammer the wheel axle shaft out of the final drive housing GNIL14TR04287AA 22 23 Retrieve the taper roller bearing NOTE Ball bearings are fitted in low duty trumpet housing GNIL14TR04288AA 23 47866583_ 02 12 2015 27 3 27 120 10 ...

Page 326: ...5 Retrieve oil seal from the housing GNIL14TR04290AA 25 26 Retrieve the taper roller bearing external spacer seal and oil seal from the trumpet NOTE During assembly insert bearing spacer over bear ing manually in heavy duty drive line NOTE Ball bearing is fitted in low duty trumpet housing GNIL14TR04291AB 26 47866583_ 02 12 2015 27 3 27 120 11 ...

Page 327: ...oil seal back by using the spe cial tool number 84261386 Check planet carrier after fitting circlip lock on axle for free play If notice any free play remove circlip lock and place suitable shim below the spacer so as to eliminate free play completely NOTE In low duty trumpet housing bearing preload is not required Before reassembling housing and covers thoroughly clean and de grease mating surfac...

Page 328: ... is moving and also with transmission in neutral 1 Wheel axle shaft bearing badly adjusted Remove final drive case and adjust bear ings 2 Faulty or defective inner components Remove final drive case and replace dam aged parts 3 Excess bull and pinion gear backlash Remove final drive case and replace dam aged parts 47866583_ 02 12 2015 27 3 27 120 13 ...

Page 329: ...nal drives 120 Final drive housing Assemble 12 Final drive housing Disassemble 5 Final drive housing Sectional view 4 Final drive housing Troubleshooting 13 Planetary and final drives General specification 3 47866583_ 02 12 2015 27 3 27 120 14 ...

Page 330: ...47866583_ 02 12 2015 27 3 27 120 15 ...

Page 331: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 332: ...SERVICE MANUAL Power Take Off PTO Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 31 ...

Page 333: ...Contents Power Take Off PTO 31 31 101 Rear mechanical control 31 1 31 110 One speed rear Power Take Off PTO 31 2 31 114 Two speed rear Power Take Off PTO 31 3 47866583_ 02 12 2015 31 ...

Page 334: ...Power Take Off PTO 31 Rear mechanical control 101 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 31 1 31 101 1 ...

Page 335: ...ntrol 101 TECHNICAL DATA Rear mechanical control General specification 3 Torque 3 Sealing 4 Special tools 5 FUNCTIONAL DATA Rear mechanical control Sectional view 6 SERVICE Rear mechanical control Remove 7 Install 11 47866583_ 02 12 2015 31 1 31 101 2 ...

Page 336: ...end Clock wise Engine speed 540 RPM standard Power Take Off PTO speed 540E RPM economical Power Take Off PTO speed 2575 RPM 2016 RPM Output shaft Number of splines Shaft diameter 6 28 86 28 96 mm 1 136 1 14 in Rear mechanical control Torque Description Thread size Torque Power Take Off PTO case mounting bolts C1 M12 x 1 25 10 00 kgf 22 05 lbf Power Take Off PTO lever plate screws C2 M8 0 90 kgf 1 ...

Page 337: ...al control GNIL14TR00831GA 1 Rear mechanical control Sealing Operation description Sealant specification Power Take Off PTO rear cover S1 LOCTITE 518 Hydraulic to transmission housing S2 LOCTITE 518 47866583_ 02 12 2015 31 1 31 101 4 ...

Page 338: ...al control GNIL14TR04296FB 1 Rear mechanical control Special tools Operation description Tools specification Power Take Off PTO rear cover seal installer 84261381 Yoke and spreader 291051 and 291052 47866583_ 02 12 2015 31 1 31 101 5 ...

Page 339: ...ntrol Rear mechanical control Sectional view GNIL14TR00826FA 1 1 Transmission input shaft 2 Power Take Off PTO engaging sleeve 3 Power Take Off PTO input shaft 4 Power Take Off PTO shaft 5 Reduction gear 47866583_ 02 12 2015 31 1 31 101 6 ...

Page 340: ...PTO rear cover to the differential housing GNIL14TR00741AA 2 4 Remove the PTO shaft assembly rear cover Remove the PTO engaging coupler 1 and retrieve PTO en gage disengage pad GNIL14TR00742AA 3 PTO levers and internal linkages CAUTION Avoid injury Handle all parts carefully Do not place your hands or fingers between parts Use Personal Protec tive Equipment PPE as indicated in this manual includin...

Page 341: ...ft GNIL14TR04303AB 4 6 Loosen set screw 1 and remove plate GNIL14TR04304AB 5 7 Remove roll pin holding differential lock fork 1 and PTO coupler fork GNIL14TR04305AB 6 8 Remove the differential pedal lever 2 by unscrewing two bolts 3 securing the bracket GNIL14TR04307AB 7 47866583_ 02 12 2015 31 1 31 101 8 ...

Page 342: ...shaft 1 and PTO lever shaft GNIL14TR04308AB 8 10 Remove PTO fork 1 GNIL14TR04309AB 9 11 Remove differential lock pedal fork 1 GNIL14TR04310AB 10 PTO input shaft cover 12 Loosen the bolts and remove the PTO input shaft cover GNIL14TR00744AA 11 47866583_ 02 12 2015 31 1 31 101 9 ...

Page 343: ...PTO Rear mechanical control 13 Loosen the bolt from the inner side of the cover plate GNIL14TR00738AA 12 14 Retrieve the inner plate and the spring from the cover GNIL14TR00739AA 13 47866583_ 02 12 2015 31 1 31 101 10 ...

Page 344: ...hanical control Rear mechanical control Install For installation follow the removal process in reverse order NOTE Torque all the bolts to correct value See Rear mechanical control Torque 31 101 47866583_ 02 12 2015 31 1 31 101 11 ...

Page 345: ...ol General specification 3 Rear mechanical control Install 11 Rear mechanical control Remove 7 Rear mechanical control Sealing 4 Rear mechanical control Sectional view 6 Rear mechanical control Special tools 5 Rear mechanical control Torque 3 47866583_ 02 12 2015 31 1 31 101 12 ...

Page 346: ...Power Take Off PTO 31 One speed rear Power Take Off PTO 110 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 31 2 31 110 1 ...

Page 347: ...Take Off PTO 31 One speed rear Power Take Off PTO 110 FUNCTIONAL DATA One speed rear Power Take Off PTO Overview 3 SERVICE One speed rear Power Take Off PTO Disassemble 4 Assemble 5 47866583_ 02 12 2015 31 2 31 110 2 ...

Page 348: ...connected and disconnected to the transmission input shaft by means of a lever 1 on the left hand side of the transmission unit Move the lever 1 backward to engage the PTO Move the lever 1 forward to disengage the PTO The rear end of the Power Take Off PTO input shaft is connected to the Power Take Off PTO output shaft through reduction gears The standard speed of 540 PTO RPM can be obtained at 25...

Page 349: ... 101 2 Remove the PTO input shaft cover Remove the PTO coupler 1 Remove the bearing 2 Remove the PTO drive shaft assembly 3 from the PTO rear cover GNIL14TR00768AA 1 3 Remove the Power Take Off PTO driven shaft along with gear 1 and take out bearing 2 if necessary NOTE Gear is the integral part of Power Take Off PTO shaft in single speed Power Take Off PTO GNIL14TR04324AB 2 47866583_ 02 12 2015 31...

Page 350: ...Power Take Off PTO One speed rear Power Take Off PTO Assemble 1 For assembly follow the disassembly process in re verse order 2 Fit Power Take Off PTO shaft seal 1 as shown in figure GNIL14TR04325AA 1 47866583_ 02 12 2015 31 2 31 110 5 ...

Page 351: ...ff PTO 31 One speed rear Power Take Off PTO 110 One speed rear Power Take Off PTO Assemble 5 One speed rear Power Take Off PTO Disassemble 4 One speed rear Power Take Off PTO Overview 3 47866583_ 02 12 2015 31 2 31 110 6 ...

Page 352: ...Power Take Off PTO 31 Two speed rear Power Take Off PTO 114 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 31 3 31 114 1 ...

Page 353: ...Off PTO 31 Two speed rear Power Take Off PTO 114 FUNCTIONAL DATA Two speed rear Power Take Off PTO Overview 3 SERVICE Two speed rear Power Take Off PTO Disassemble 4 Inspect 6 Assemble 7 47866583_ 02 12 2015 31 3 31 114 2 ...

Page 354: ...e of the transmission unit The rear end of the Power Take Off PTO input shaft is connected to the Power Take Off PTO output shaft through reduction gears The standard speed of 540 PTO RPM can be obtained at 2575 engine rpm Shift lever forward to get normal 540 PTO RPM and shift rearward to get ground speed or 540E PTO 540 Economy RPM can be obtained at 2016 engine RPM Power Take Off PTO Engine Lev...

Page 355: ...4TR00745AA 1 2 Remove the circlip lock 1 needle roller bearing Take out the hollow Power Take Off PTO shaft GNIL14TR04312AB 2 3 Retrieve the needle roller bearing 1 Remove the PTO input shaft cover Remove the Power Take Off PTO drive shaft assembly 2 from the rear cover GNIL14TR00749AA 3 4 Remove Power Take Off PTO output shaft and gear assembly 1 GNIL14TR00750AA 4 47866583_ 02 12 2015 31 3 31 114...

Page 356: ...TO Two speed rear Power Take Off PTO 5 To dismantle Power Take Off PTO gears assembly use special tool number 291051 and 291052 as shown in figure to remove bearing GNIL14TR00751AA 5 47866583_ 02 12 2015 31 3 31 114 5 ...

Page 357: ... Power Take Off PTO Two speed rear Power Take Off PTO Inspect PTO shaft assembly inspection Check the gears shaft and bearings for wear and dam ages If required replace by new parts GNIL14TR04319AA 1 47866583_ 02 12 2015 31 3 31 114 6 ...

Page 358: ...114 Refer to figure for correct orientation of the gears and sleeve Check seals and replace if damaged Fit the Power Take Off PTO oil seal in the Power Take Off PTO rear cover with the help of special tool number 84261386 GNIL14TR04318AA 1 Before reassembling Power Take Off PTO cover Thoroughly clean and degrease mating surfaces and apply a 2 00 mm 0 08 in bead of sealant following the pattern sho...

Page 359: ...Power Take Off PTO Two speed rear Power Take Off PTO GNIL14TR04320GA 2 47866583_ 02 12 2015 31 3 31 114 8 ...

Page 360: ...ar Power Take Off PTO 114 Two speed rear Power Take Off PTO Assemble 7 Two speed rear Power Take Off PTO Disassemble 4 Two speed rear Power Take Off PTO Inspect 6 Two speed rear Power Take Off PTO Overview 3 47866583_ 02 12 2015 31 3 31 114 9 ...

Page 361: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 362: ...SERVICE MANUAL Brakes and controls Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 33 ...

Page 363: ...Contents Brakes and controls 33 33 120 Mechanical service brakes 33 1 47866583_ 02 12 2015 33 ...

Page 364: ...Brakes and controls 33 Mechanical service brakes 120 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 33 1 33 120 1 ...

Page 365: ...Special tools 3 Torque 3 Sealing 4 FUNCTIONAL DATA Mechanical service brakes Exploded view 6 Overview 7 Sectional view 8 SERVICE Mechanical service brakes Remove 9 Inspect 12 Install 13 Brake control pedals and shafts Remove 15 Adjust 17 DIAGNOSTIC Mechanical service brakes Troubleshooting 18 47866583_ 02 12 2015 33 1 33 120 2 ...

Page 366: ... 20W30 Nominal brake disc thickness 4 65 mm 0 183 in Brake pedal free play 50 55 mm 1 97 2 17 in Mechanical service brakes Special tools Description Tool number Installer brake boot in trumpet housing 84261390 Installer rubber boot outer in brake linkage groove 84261391 Mechanical service brakes Torque Description Thread size Torque Hand brake pawl assembly mounting bolt C1 M12 x 1 25 10 kgf 22 lb...

Page 367: ...chanical service brakes GNIL14TR00832GA 1 Mechanical service brakes Sealing Operation description Sealant specification Buckle up of rear axle housing to differential housing S1 LOCTITE 518 47866583_ 02 12 2015 33 1 33 120 4 ...

Page 368: ...Brakes and controls Mechanical service brakes GNIL14TR04327FB 1 47866583_ 02 12 2015 33 1 33 120 5 ...

Page 369: ...Brakes and controls Mechanical service brakes Mechanical service brakes Exploded view GNIL14TR00841GB 1 47866583_ 02 12 2015 33 1 33 120 6 ...

Page 370: ...s to contact the rotating brake discs which in turn contact the inner faces of the brake housing 8 and differential support and back up discs This movement increases the axial force on the housing support back up disc and actuator and produce brake torque This action causes the axle shaft hence the associated driving wheel of the tractor to slow down and then stop rotating completely On release of...

Page 371: ...anical service brakes Mechanical service brakes Sectional view GNIL14TR00833FA 1 1 Final drive housing 2 Actuator return spring 3 Inner friction plate 4 Actuating discs 5 Outer friction plate 47866583_ 02 12 2015 33 1 33 120 8 ...

Page 372: ...om the transmission 1 Remove the pin 1 and disconnect the brake linkage GNIL14TR00789AA 1 2 Wrap chain around final drive housing and loosen bolts 1 Remove the final drive housing GNIL14TR04276AB 2 3 Place the trumpet housing assembly on plane surface GNIL14TR04336AA 3 4 Remove the linkage 1 GNIL14TR00792AA 4 47866583_ 02 12 2015 33 1 33 120 9 ...

Page 373: ...emove the nut and spring Remove the circlip GNIL14TR00791AA 5 6 Remove brake disc 1 and shaft 2 GNIL14TR04277AB 6 7 Remove the brake actuator assembly 1 GNIL14TR04278AB 7 8 Remove second brake disc GNIL14TR00779AA 8 47866583_ 02 12 2015 33 1 33 120 10 ...

Page 374: ...kes and controls Mechanical service brakes 9 Remove intermediate plate and third brake disc GNIL14TR00780AA 9 10 Remove dual brake support 1 as shown GNIL14TR04279AB 10 47866583_ 02 12 2015 33 1 33 120 11 ...

Page 375: ... Inspect 1 Inspect the brake flange friction face for wear and dam age replace if necessary 2 Inspect the inner and outer brake discs if badly scored worn or cracked replace NOTE Brake discs thickness should be minimum 4 300 mm 0 169 in 47866583_ 02 12 2015 33 1 33 120 12 ...

Page 376: ...arts Use special tool number 84261390 to fit the brake rubber boot in the brake linkage groove and brake rubber brake boot with special tool number 84261391 in trumpet housing GNIL14TR04340AA 1 Before reinstalling the rear axle housing thoroughly clean and degrease mating surfaces and apply a bead of liquid gasket of approx 2 000 mm 0 079 in of diameter Check seals for wear and damage and replace ...

Page 377: ...Brakes and controls Mechanical service brakes GNIL14TR04342FA 3 47866583_ 02 12 2015 33 1 33 120 14 ...

Page 378: ...t hand and right hand side brake link ages GNIL14TR00766AA 1 2 Remove the brake pedal springs Remove the clutch pedal springs GNIL14TR00782AA 2 3 Remove the conical screw 1 that locks the brake shaft GNIL14TR00812AA 3 4 Slide out both left hand and right hand side brake ped als 1 from brake shaft 2 GNIL14TR04332AB 4 47866583_ 02 12 2015 33 1 33 120 15 ...

Page 379: ...ke linkage removal 5 Remove split pin from hand brake linkage 6 Pull out hand brake lever along with linkage rod from the linkage assembly GNIL14TR04333AA 5 7 Loosen the bolt 1 and remove hand brake pawl 2 GNIL14TR04334AB 6 47866583_ 02 12 2015 33 1 33 120 16 ...

Page 380: ...ront and rear unlock the brake pedals and release the parking brake lever Re lease locking clamp loosen locknut 1 and rotate the yoke 2 clockwise to reduce the play and anti clock wise to increase the play figure 2 3 Repeat the same procedure for the left brake pull rod 4 Lock the brake pedals together and road test to ensure that the brakes are balanced and will stop the tractor in a straight lin...

Page 381: ...rakes not equally adjusted Adjust Wrong tire pressure Inflate tires to correct pressure Wrong liners on one side Replace discs Brakes noisy Oil contamination Check and change with recommended oil Wrong brake disc Replace brake discs Brakes remain applied when pedals are released Seized brake actuating linkages Clean and lubricate linkages Pedals are hard to operate Seized brake actuating linkages ...

Page 382: ...es General specification 3 Mechanical service brakes Inspect 12 Mechanical service brakes Install 13 Mechanical service brakes Overview 7 Mechanical service brakes Remove 9 Mechanical service brakes Sealing 4 Mechanical service brakes Sectional view 8 Mechanical service brakes Special tools 3 Mechanical service brakes Torque 3 Mechanical service brakes Troubleshooting 18 47866583_ 02 12 2015 33 1 ...

Page 383: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 384: ...SERVICE MANUAL Hydraulic systems Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 35 ...

Page 385: ...ic systems 35 1 35 100 Main lift system 35 2 35 104 Fixed displacement pump 35 3 35 204 Remote control valves 35 4 35 300 Reservoir cooler and filters 35 5 35 355 Hydraulic hand control 35 6 35 359 Main control valve 35 7 47866583_ 02 12 2015 35 ...

Page 386: ...Hydraulic systems 35 Hydraulic systems 000 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 35 1 35 000 1 ...

Page 387: ...draulic systems 35 Hydraulic systems 000 FUNCTIONAL DATA Hydraulic systems Overview 3 Hydraulic schema 4 Component identification 6 DIAGNOSTIC Hydraulic systems Troubleshooting 8 47866583_ 02 12 2015 35 1 35 000 2 ...

Page 388: ...of engine timing gear Oil is drawn from transmission case through filter The pump supplies constant oil flow according to engine speed High pressure oil enters the distributor valve located at the front of the lift assembly which controls the raising and lowering of the lift All excess oil flow produced by the hydraulic pump is returned direct to the gear box through the control valve spool locate...

Page 389: ...systems Hydraulic systems Hydraulic schema GNIL14TR00817GA 1 Schematic view of hydraulic system 1 Hydraulic pump 4 Delivery line 2 Hydraulic filter 5 Oil sump transmission housing 3 Suction line 47866583_ 02 12 2015 35 1 35 000 4 ...

Page 390: ...Hydraulic systems Hydraulic systems GNIL14TR00818GA 2 Hydraulic circuit diagram 47866583_ 02 12 2015 35 1 35 000 5 ...

Page 391: ...r pump 1 GNIL14TR00519AA 1 Filter Full flow spin on type filter 1 mounted on right side of the engine on suction pump GNIL14TR00519AA 2 Mechanical hydraulic lift assembly Mounted on top of transmission housing comprising of following components Position control lever 1 Draft control lever 2 GNIL14TR00580AA 3 47866583_ 02 12 2015 35 1 35 000 6 ...

Page 392: ...c systems Hydraulic systems Distributor 3 Response control valve 4 GNIL14TR00804AA 4 Draft sensing unit 8 Lift arms 9 Internal linkages and cylinder assembly GNIL14TR04568AB 5 47866583_ 02 12 2015 35 1 35 000 7 ...

Page 393: ... O rings Replace O rings as necessary Relief valve not adjusted correctly Adjust relief valve to specification Worn lift cylinder piston seal Replace damaged seal Lift arms cycle up and down with load applied with engine running Lift cylinder piston seal damaged Replace piston seal Discharge valve not adjusted correctly Adjust sensitivity of control valve Lift check valve not seating properly Insp...

Page 394: ...c systems 35 Hydraulic systems 000 Hydraulic systems Component identification 6 Hydraulic systems Hydraulic schema 4 Hydraulic systems Overview 3 Hydraulic systems Troubleshooting 8 47866583_ 02 12 2015 35 1 35 000 9 ...

Page 395: ...47866583_ 02 12 2015 35 1 35 000 10 ...

Page 396: ...Hydraulic systems 35 Main lift system 100 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 35 2 35 100 1 ...

Page 397: ...neral specification 3 Torque 3 Sealing 4 Special tools 5 FUNCTIONAL DATA Main lift system Dynamic description 6 SERVICE Main lift system Remove 11 Install 13 Disassemble 14 Assemble 21 Adjust 22 Inspect 27 DIAGNOSTIC Main lift system Troubleshooting 29 47866583_ 02 12 2015 35 2 35 100 2 ...

Page 398: ...00 0 kg 3306 9 lb Pressure regulating valve setting 190 bar 2755 psi Cylinder safety valve opening pressure 205 0 bar 2972 5 psi Implement attachment Type 3 Point hitch Category I II Draft control Through top link Maximum lifting capacity at hitch point 1100 kg 2425 lb and 1500 0 kg 3306 9 lb for heavy duty Main lift system Torque Description Thread size Torque Bolts lift to housing C1 M10 x 1 25 ...

Page 399: ...raulic systems Main lift system GNIL14TR00819GA 1 Main lift system Sealing Operation description Sealant specification Lift housing to transmission housing S1 LOCTITE 518 47866583_ 02 12 2015 35 2 35 100 4 ...

Page 400: ...4TR04583FB 1 Main lift system Special tools Tool description Tool number Installer lift arm seal with protector 9970873 Socket for spool height adjustment 9970874 Adapter hydraulic pressure checking 9970877 47866583_ 02 12 2015 35 2 35 100 5 ...

Page 401: ...nt movement is proportional to the movement range fixed by means of lever 1 Draft control Move the position control lever 2 fully down have the implement penetrated into the ground till reaching the desired depth by gradually moving the lever 2 down The implement depth reached is proportional to the draft determined by soil hardness In this condition the rock shaft keeps the draft required automat...

Page 402: ...s the implement from excessively pen etrating into the ground causing a not very uniform work when coming up against a less hard ground For raising and moving the implement penetrated at the end and beginning of each pass acting on position lever 1 only NOTE It is not correct to find the position with the draft lever 2 because the lifting and lowering of arms with this lever changes with the top l...

Page 403: ...ection and by means of the link 14 will cause position cam 6 to rotate clockwise When the roller 5 meets the inclined plane of the cam 6 it allows the anti clockwise rotation of the flywheel 7 that by means of a friction shock absorber 8 rotates the lever 9 in a clockwise direction which is pushed by the spring of the control valve shaft 21 which moves to position N neutral phase and thus blocking...

Page 404: ...sion rod 17 causes roller 11 to slide on flywheel 7 The roller 11 when it meets the inclined plane of the draft cam 12 permits the counter clockwise rotation of fly wheel 7 which by means of shock absorber 8 will rotate transmission lever 9 in a clockwise manner thus leaving distributor shaft 21 free to move into neutral position N and continuing the movement of lever 2 in the discharge position S...

Page 405: ...ition control lever 1 flywheel 7 roller 4 and position cam 6 the distributor shaft 21 is prevented from entering the lowering position S and therefore the arms cannot sink even though the traction force acting on the top link point 20 will tend to diminish and putting stress on the tension rod 18 in the direction of arrow negative This condition will not prevent the rock shaft from operating with ...

Page 406: ... footwear Failure to comply could result in death or serious injury W0208A Remove the hydraulic lift from the rear axle housing as follows 1 Remove three point linkages top link lower link and lift rod from the tractor 76099304N 1 2 Disconnect delivery pipe and return pipe from the lift assembly GNIL14TR00800AA 2 3 Disconnect the wiring coupler Loosen the bolts 1 Remove the operator s seat from th...

Page 407: ...aulic lift housing to trans mission housing 5 Lift the hydraulic lift assembly using suitable hoist and place it on a flat surfaced table NOTICE Never lift the housing by holding distributor knobs and delicate parts GNIL14TR00799AA 4 47866583_ 02 12 2015 35 2 35 100 12 ...

Page 408: ...44A Refit the hydraulic lift on the transmission housing as follows 1 Re installation follows the removal procedure in re verse 2 Before refitting the hydraulic lift in the rear transmission casing clean and degrease the mating surfaces thor oughly and apply a strip of sealing compound of about 2 00 mm 0 08 in diameter as shown in the figure 3 Apply the torque settings GNIL14TR04609AA 1 47866583_ ...

Page 409: ...ply could result in death or serious injury W0208A NOTE Draft sensing unit and related external linkages can be disassembled and assembled with the lift unit mounted on the tractor Draft sensing unit Removal 1 Loosen the bolts 1 from the sensing unit GNIL14TR04617AB 1 2 Remove the lock 1 and remove draft link 2 GNIL14TR04618AB 2 3 Loosen bolts 1 and set screw 4 Remove the pin as shown in figure 5 ...

Page 410: ...emble roller 2 springs 3 cover 4 flange 5 from the sensing unit Rear lift internal controls removal 8 Remove the lift assembly from the transmission hous ing and fix on a rotary stand See Main lift system Remove 35 100 GNIL14TR04642AA 5 9 Loosen the set screws 1 GNIL14TR04624AB 6 47866583_ 02 12 2015 35 2 35 100 15 ...

Page 411: ...14TR04625AB 7 NOTE Retrieve the seal 1 from head of cylinder GNIL14TR04626AB 8 11 Remove the piston 1 from the cylinder by pushing with a suitable aluminium rod from the front side GNIL14TR04627AB 9 12 Remove locks and disassemble lever 1 GNIL14TR04631AB 10 47866583_ 02 12 2015 35 2 35 100 16 ...

Page 412: ...633AB 11 14 Remove the lock 1 from the compensator pin GNIL14TR04632AB 12 15 Unscrew the compensator pin until face of the pin comes out of the compensator GNIL14TR04634AB 13 16 Remove linkages as shown in figure GNIL14TR04635AB 14 47866583_ 02 12 2015 35 2 35 100 17 ...

Page 413: ...Remove link 1 GNIL14TR04636AB 15 18 Unscrew locking screw 1 and remove position con trol cam 2 and bracket 3 GNIL14TR04637AB 16 19 Remove dowel pin 1 GNIL14TR04638AB 17 20 Remove cam 1 GNIL14TR04639AB 18 47866583_ 02 12 2015 35 2 35 100 18 ...

Page 414: ...rew 1 and disassemble lever 2 along with link 3 GNIL14TR04641AB 20 Lift arm shaft removal 23 Remove lift assembly from the tractor and fix it on a rotary stand Refer to Main lift system Remove 35 100 GNIL14TR04642AA 21 24 Remove the circlip 1 from lift arm shaft GNIL14TR04643AB 22 47866583_ 02 12 2015 35 2 35 100 19 ...

Page 415: ...acilitate the assembly in original posi tion GNIL14TR04644AB 23 26 Repeat the same for the other side lift arm GNIL14TR04645AB 24 27 Remove the locking sensor 1 locking crank and shaft 28 Push the shaft from left hand side towards right hand side by hammering gently using aluminium or copper rod GNIL14TR04646AA 25 47866583_ 02 12 2015 35 2 35 100 20 ...

Page 416: ...ims 4 Refer to page for correct settings GNIL14TR04622AA 1 Rear lift internal controls 5 Re assembling follows disassembly procedure in re verse Lift arm shaft 6 Reinstall the shaft and lift arm in the lift housing observ ing the following Reinstallation follows the removal procedure in re verse Refer to Main lift system Disassemble 35 100 from step 6 to step 1 See Main lift system Install 35 100 ...

Page 417: ...taining fixed the levers 1 and 2 and with a 13 0 mm 0 5 in open end wrench rotate slowly in an anti clockwise direction the position control shaft 5 so as to raise the arms to their maximum raised position which is determined by the internal hydraulic limit stop Since during the functioning of the position control the hydraulic limit stop must not be triggered it is neces sary to have a safety mar...

Page 418: ... lowest position With the motor running at minimum RPM slowly raise the draft control lever 2 The adjustment of the draft lever 2 is correct when it is moved upward to the 6 8 sign on the sector and this allows the arms to be completely raised If the lever 2 raises completely the arms before arriv ing at the 6 8 sign on the sector then the measurement L of the rod T must be shortened If the lever ...

Page 419: ...r cover 4 must rest against the flange 3 In this condition the spring M is set to a preload of 0 30 0 60 mm 0 01 0 02 in Before assembling the complete reaction assembly to the rockshaft housing a pre assembly of the spring M is needed in order to obtain a measurement of about 8 40 mm 0 33 in After carrying out the reaction assembly a definitive ad justment is made Keep the screw V fixed with an 8...

Page 420: ...l valve face is carried out after making all the adjustments sensitivity of control valve position control lever draft control lever With the rock shaft s arms completely lowered and with out loads or implements on the three point linkage neu tral position position the two control levers 1 and 2 at their lower position against the backstop F In this position push the push rod and verify with the a...

Page 421: ...Hydraulic systems Main lift system GNIL14TR04655FB 4 47866583_ 02 12 2015 35 2 35 100 26 ...

Page 422: ...letely the pre selector P in order to block the oil passage to the rock shaft cylinder To obtain the acting of external cylinder move up slowly the draft lever 2 If the top link bracket is in neutral position without any implement attached the effect starts when the lever 2 is between num bers 9 6 on the sector To obtain the stop of the acting move back down a little the draft lever To obtain the ...

Page 423: ...stem Therefore after having reached the required movement of the cylinder it is important to not forget to move back down a little the lever 2 in order to stop the cylinder or to discharge the oil 47866583_ 02 12 2015 35 2 35 100 28 ...

Page 424: ...gs Relief and safety valves out or calibration Control calibration of the valves Poor pump efficiency Replace the pump Excessive loss of oil from control valve Overhaul the control valve The rock shaft supports loads with difficulty Piston gasket worn Replace the gasket When the motor is off Oil leakage from safety valve Remove control valve and adjust valve Oil leakage from check valve Remove the...

Page 425: ...emble 14 Main lift system Dynamic description 6 Main lift system General specification 3 Main lift system Inspect 27 Main lift system Install 13 Main lift system Remove 11 Main lift system Sealing 4 Main lift system Special tools 5 Main lift system Torque 3 Main lift system Troubleshooting 29 47866583_ 02 12 2015 35 2 35 100 30 ...

Page 426: ...Hydraulic systems 35 Fixed displacement pump 104 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 35 3 35 104 1 ...

Page 427: ...ntents Hydraulic systems 35 Fixed displacement pump 104 TECHNICAL DATA Fixed displacement pump General specification 3 SERVICE Fixed displacement pump Remove 4 Install 6 47866583_ 02 12 2015 35 3 35 104 2 ...

Page 428: ...andem with the steering pump drawing oil from transmission housing Location On the right hand side of the engine Mounting Fitted on engine timing case and driven by timing gears Make Rexroth Bosch Group Drive Engine timing gears Rotation seen from the free end of the drive shaft Anti clockwise Displacement 16 cm per revolution Max rotational speed 3300 RPM Flow at 1500 RPM 210 bar 21 12 L min 4786...

Page 429: ...ydraulic hump GNIL14TR00729AA 1 2 Disconnect the hydraulic delivery pipe on the pump and remove the connector 1 GNIL14TR00730AA 2 3 Remove the hydraulic filter and connector between hy draulic filter and pump GNIL14TR00731AA 3 4 Remove the power steering suction pipe GNIL14TR00732AA 4 47866583_ 02 12 2015 35 3 35 104 4 ...

Page 430: ...Hydraulic systems Fixed displacement pump 5 Loosen the allen screws and remove the hydraulic pump GNIL14TR00733AA 5 47866583_ 02 12 2015 35 3 35 104 5 ...

Page 431: ...Hydraulic systems Fixed displacement pump Fixed displacement pump Install For installation follow the removal process in reverse order 47866583_ 02 12 2015 35 3 35 104 6 ...

Page 432: ...ndex Hydraulic systems 35 Fixed displacement pump 104 Fixed displacement pump General specification 3 Fixed displacement pump Install 6 Fixed displacement pump Remove 4 47866583_ 02 12 2015 35 3 35 104 7 ...

Page 433: ...47866583_ 02 12 2015 35 3 35 104 8 ...

Page 434: ...Hydraulic systems 35 Remote control valves 204 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 35 4 35 204 1 ...

Page 435: ...Contents Hydraulic systems 35 Remote control valves 204 SERVICE Remote control valve Remove 3 Remove 5 Install 7 Mid mount remote control valve Remove 8 Install 10 47866583_ 02 12 2015 35 4 35 204 2 ...

Page 436: ...e to comply could result in death or serious injury W1114A 1 Loosen the set screw and remove the remote control valve lever 2 Remove the two circlip 1 and 2 from position control lever Remove the position control lever 3 GNIL14TR00646AA 1 3 Loosen the two bolts 1 and remove the quadrant 2 GNIL14TR00647AA 2 4 Loosen the bolts 1 and remove the draft control lever 2 GNIL14TR00648AA 3 47866583_ 02 12 ...

Page 437: ...stems Remote control valves 5 1 Remove the hydraulic pipes 1 on remote control valve 2 Loosen the bolts 2 and remove the plate 3 Remove the remote control valve GNIL14TR00649AA 4 47866583_ 02 12 2015 35 4 35 204 4 ...

Page 438: ...to comply could result in death or serious injury W1114A 1 1 Loosen the set screw 1 Remove the remote con trol valve lever 2 2 Similarly remove the another remote control valve lever GNIL14TR00659AA 1 2 Remove the two circlip 1 and 2 from position control lever Remove the position control lever 3 GNIL14TR00646AA 2 3 Loosen the two bolts 1 and remove the quadrant 2 GNIL14TR00647AA 3 47866583_ 02 12...

Page 439: ...e draft control lever 2 GNIL14TR00648AA 4 5 Loosen the bolt 1 GNIL14TR00658AA 5 6 Loosen the bolts 1 Remove the hoses 2 GNIL14TR00657AA 6 7 1 Loosen the bolts 1 2 Remove the plate 2 3 Remove the two remote control valves 3 GNIL14TR00652AA 7 47866583_ 02 12 2015 35 4 35 204 6 ...

Page 440: ...ure from the hydraulic system before installing the kit Failure to comply could result in death or serious injury W1114A NOTE For installation follow the removal process in reverse order Lubricate the seal rings 1 lightly with petroleum jelly This will help to hold rings in position during installation GNIL14TR00650AA 1 47866583_ 02 12 2015 35 4 35 204 7 ...

Page 441: ...ic EH con trol Remove 55 512 2 Disconnect the hydraulic delivery pipe between hy draulic pump and mid mount valve GNIL14TR00783AA 1 3 Disconnect the hydraulic delivery pipe between mid mount valve and main control valve GNIL14TR00843AA 2 4 Disconnect the hydraulic line between the mid mount valve and hydraulic lift body GNIL14TR00842AA 3 47866583_ 02 12 2015 35 4 35 204 8 ...

Page 442: ...Hydraulic systems Remote control valves 5 Loosen the bolts 1 and remove the mid mount valve from the mounting bracket GNIL14TR00844AA 4 47866583_ 02 12 2015 35 4 35 204 9 ...

Page 443: ...ne between the mid mount valve and hydraulic lift body GNIL14TR00842AA 2 3 Connect the hydraulic delivery pipe between mid mount valve and main control valve GNIL14TR00843AA 3 4 Connect the hydraulic delivery pipe between hydraulic pump and mid mount valve GNIL14TR00783AA 4 5 Connect the joystick cables See Joystick and Elec tric Hydraulic EH control Install 55 512 47866583_ 02 12 2015 35 4 35 204...

Page 444: ...ote control valves 204 Mid mount remote control valve Install 10 Mid mount remote control valve Remove 8 Remote control valve Install 7 Remote control valve Remove 3 Remote control valve Remove 5 47866583_ 02 12 2015 35 4 35 204 11 ...

Page 445: ...47866583_ 02 12 2015 35 4 35 204 12 ...

Page 446: ...Hydraulic systems 35 Reservoir cooler and filters 300 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 35 5 35 300 1 ...

Page 447: ...Contents Hydraulic systems 35 Reservoir cooler and filters 300 SERVICE Oil filters Remove 3 Install 4 47866583_ 02 12 2015 35 5 35 300 2 ...

Page 448: ... and filters Oil filters Remove 1 Loosen the clamp and remove the suction pipe from the hydraulic filter GNIL14TR00725AA 1 2 Loosen the allen screws 1 and remove the hydraulic filter GNIL14TR00728AA 2 47866583_ 02 12 2015 35 5 35 300 3 ...

Page 449: ...Hydraulic systems Reservoir cooler and filters Oil filters Install For installation follow the reverse order of removal 47866583_ 02 12 2015 35 5 35 300 4 ...

Page 450: ...Index Hydraulic systems 35 Reservoir cooler and filters 300 Oil filters Install 4 Oil filters Remove 3 47866583_ 02 12 2015 35 5 35 300 5 ...

Page 451: ...47866583_ 02 12 2015 35 5 35 300 6 ...

Page 452: ...Hydraulic systems 35 Hydraulic hand control 355 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 35 6 35 355 1 ...

Page 453: ...Contents Hydraulic systems 35 Hydraulic hand control 355 FUNCTIONAL DATA Hydraulic hand control Overview 3 SERVICE Hydraulic hand control Disassemble 5 Assemble 7 47866583_ 02 12 2015 35 6 35 355 2 ...

Page 454: ...i mounted equipment may interfere with and cause damage to tractor sheet metal To avoid damage check for clearance between tractor and implements Position control operation Position control provides accurate control of implements such as sprayers rakes rotary tillers etc that operate above the ground Once set position control will maintain the selected implement height NOTE Always set the system t...

Page 455: ... same field it may be necessary to use the draft control and position control in combination When starting work lower the im plement to the required depth by means of the draft control lever 1 When the implement reaches the required depth raise the position control lever 2 back until the lift arms tend to rise The lift linkage is now in draft control but the position control function prevents the ...

Page 456: ...assembled only with the lift on a work bench or on a rotary stand It is possible to remove only position control lever when the lift assembly is mounted on the tractor 1 Remove the lift from the transmission housing and place on a work bench or fix on a rotary stand GNIL14TR04610AB 1 2 Loosen set screws 1 and remove position control lever hub along with nylon washer NOTE Nylon washers can be remov...

Page 457: ...raft control lever is welded on draft control shaft Re move the position control shaft and draft control shaft to remove the draft control lever internal linkages 1 Remove set screw 2 Remove linkages from the shafts NOTE Remove hydraulic linkages to remove set screw GNIL14TR04614AB 5 6 Remove set screw 1 to remove shaft GNIL14TR04615AA 6 47866583_ 02 12 2015 35 6 35 355 6 ...

Page 458: ... control Assemble 1 Reassemble the lift external controls following the dis assemble procedure in reverse 2 Check the O rings on the draft control shaft for any damage If necessary replace by new O rings GNIL14TR04616AB 1 47866583_ 02 12 2015 35 6 35 355 7 ...

Page 459: ...Index Hydraulic systems 35 Hydraulic hand control 355 Hydraulic hand control Assemble 7 Hydraulic hand control Disassemble 5 Hydraulic hand control Overview 3 47866583_ 02 12 2015 35 6 35 355 8 ...

Page 460: ...Hydraulic systems 35 Main control valve 359 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 35 7 35 359 1 ...

Page 461: ...Contents Hydraulic systems 35 Main control valve 359 FUNCTIONAL DATA Main control valve Overview 3 SERVICE Main control valve Remove Distributor assembly 8 Install 9 47866583_ 02 12 2015 35 7 35 359 2 ...

Page 462: ...mber 5 of the differential valve 2 directly to the discharge through hole 6 The oil coming from the pump enters the annular duct 8 and moves the differential valve 2 upwards which then opens the discharge hole 7 and enables the oil to go to the tank The oil contained in the cylinder 9 is kept under pressure by the check valve 3 by the discharge valve 4 and safety valve 10 connected to the cylinder...

Page 463: ...Hydraulic systems Main control valve GNIL14TR00834GA 1 47866583_ 02 12 2015 35 7 35 359 4 ...

Page 464: ...gh annular duct 8 and holes 12 and 13 making in this way the valve itself to close The oil from the pump finding the differential valve 2 closed goes to cylinder pass the hole 14 opens the check valve 3 enters in the annular duct 11 and enters the chamber 9 The lifting speed depends on the pump RPM In this phase the maximum lifting pressure is controlled by the safety valve 15 that is connected to...

Page 465: ...harge hole 7 and enables the oil to go to the tank At the same time the pressure oil contained in the cylinder 9 flows to the tank therefore causing the lowering of the arms From chamber 9 the oil goes into the annular duct 11 passing the lowering speed regulation valve 16 through the connecting hole 17 enter into the discharge valve 4 that is kept open from the spool 1 and goes to discharge from ...

Page 466: ...Hydraulic systems Main control valve GNIL14TR00836GA 3 47866583_ 02 12 2015 35 7 35 359 7 ...

Page 467: ... footwear Failure to comply could result in death or serious injury W0208A 1 Loosen the bolts 1 and remove distributor assembly from lift housing NOTE Distributor assembly is not serviceable Replace complete assembly if found defective 2 Insert the distributor assembly back on the lift assembly and tighten the bolts 1 GNIL14TR00798AA 1 NOTE Check the O rings 1 for any damage on distributor assembl...

Page 468: ...Hydraulic systems Main control valve Main control valve Install For installation follow the reverse order of removal 47866583_ 02 12 2015 35 7 35 359 9 ...

Page 469: ...Index Hydraulic systems 35 Main control valve 359 Main control valve Install 9 Main control valve Overview 3 Main control valve Remove Distributor assembly 8 47866583_ 02 12 2015 35 7 35 359 10 ...

Page 470: ...47866583_ 02 12 2015 35 7 35 359 11 ...

Page 471: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 472: ...SERVICE MANUAL Steering Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 41 ...

Page 473: ...Contents Steering 41 41 101 Steering control 41 1 41 200 Hydraulic control components 41 2 41 206 Pump 41 3 41 216 Cylinders 41 4 47866583_ 02 12 2015 41 ...

Page 474: ...Steering 41 Steering control 101 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 41 1 41 101 1 ...

Page 475: ... 41 Steering control 101 TECHNICAL DATA Steering control Special tools 3 FUNCTIONAL DATA Steering control Overview Hydrostatic steering 4 DIAGNOSTIC Steering control Troubleshooting 10 47866583_ 02 12 2015 41 1 41 101 2 ...

Page 476: ...tools Description Tool number Steering wheel puller 380001672 and 380003008 Adapter power steering pressure check includes in the set of hydraulic pressure kit 292870 291318 Power steering rotor spring installer 292927 47866583_ 02 12 2015 41 1 41 101 3 ...

Page 477: ...ering control Overview Hydrostatic steering GNIL14TR00870FA 1 D1 Control valve P Hydraulic pump E Filter cartridge S Return to tank H Power cylinder T Reservoir M Pump outlet line V Steering wheel 47866583_ 02 12 2015 41 1 41 101 4 ...

Page 478: ...Steering Steering control GNIL14TR04488JB 2 47866583_ 02 12 2015 41 1 41 101 5 ...

Page 479: ...Steering Steering control 47866583_ 02 12 2015 41 1 41 101 6 ...

Page 480: ... 1 and rotary valve 5 27 Oil passage to right hand side cylinder chamber piston rod side r1 r2 Sections through DANFOSS OSPC 100 control valve 29 Thrust bearing 1 Drive pin 31 Seals 2 Sleeve return springs 32 Dust excluder 3 Control valve body 33 Cylinder safety valves 4 Check valve 34 Make up valves 5 Rotary valve 35 O rings 6 Valve seat sleeve 36 Valve adjusting screw 7 Rotor drive shaft 37 Plug...

Page 481: ...gure 2 section D D connected instant by instant with the rotor recesses during the actuation phase Six exhaust passages 19 line up with ports 20 see figure 2 section E E communicating with the power cylinder Once the gap G is eliminated valve 5 positively transmits steering wheel input to both sleeve 6 and rotor 9 through pin 1 and shaft 7 Diagrams e and f show the principle of operation at start ...

Page 482: ...l Operation of the above valves eliminates continuous steering wheel correction and prevents front wheel shimmy hydraulic circuit failure and damage to the steering linkage GNIL14TR04489FB 3 47866583_ 02 12 2015 41 1 41 101 9 ...

Page 483: ... are necessary snake like driving Leaf spring without spring force or broken Replace leaf springs Spring in double shock valve broken Replace shock valve Gear wheel set worn Replace gear wheel set Cylinder seized or piston seals worn Replace defective parts Neutral position of steering wheel cannot be obtained i e there is a tendency of Motoring Steering Column and steering unit out of line Align ...

Page 484: ...Steering is too slow and heavy when trying to turn quickly Insufficient oil supply to steering unit pump defective or number of revolutions too low Replace pump or increase number of revo lutions Relief valve setting too low Adjust valve to correct setting Relief valve sticking owing to dirt Clean the valve Spool in priority valve sticking owing to dirt Clean the valve check that spool moves easil...

Page 485: ...Index Steering 41 Steering control 101 Steering control Overview Hydrostatic steering 4 Steering control Special tools 3 Steering control Troubleshooting 10 47866583_ 02 12 2015 41 1 41 101 12 ...

Page 486: ...Steering 41 Hydraulic control components 200 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 41 2 41 200 1 ...

Page 487: ...0 SERVICE Hydraulic steering oil reservoir Remove 3 Power steering control valve Remove 4 Disassemble 5 Cleaning 9 Inspect 10 Lubricate 11 Assemble 12 Install 23 Steering circuit relief valve Pressure test 24 Adjust 25 47866583_ 02 12 2015 41 2 41 200 2 ...

Page 488: ...draulic steering oil reservoir Remove 1 Lift the front hood 2 Disconnect the hoses from the steering oil reservoir GNIL14TR00758AA 1 3 Loosen the bolts and remove the steering oil reservoir GNIL14TR00759AA 2 47866583_ 02 12 2015 41 2 41 200 3 ...

Page 489: ... 2 To gain access to the steering motor Remove tractor rear hood Remove fuel tank For removal procedure please refer to Engine section 3 1 Remove the four bolts 1 at the base of the steering column 2 Slide out the steering motor from the steering col umn 3 Remove bolts 2 from bracket to take out starting motor 4 Disconnect the four steering pipes 3 GNIL14TR00740AA 1 Disconnect the four supply retu...

Page 490: ... in a vice 2 Remove the end cover bolts 6 plus one special screw GNIL14TR04492AA 1 3 Remove the end cover sideways GNIL14TR04493AA 2 4 Lift the gear wheel set with spacer fitted off the unit Take out the two O rings GNIL14TR04494AA 3 5 Remove cardan shaft GNIL14TR04495AA 4 47866583_ 02 12 2015 41 2 41 200 5 ...

Page 491: ...R04496AA 5 7 Screw out the threaded bush over the check valve GNIL14TR04497AA 6 8 Remove O ring GNIL14TR04498AA 7 9 Shake out the check valve ball and suction valve pins and balls NOTE Replace pins prior to the reassembly GNIL14TR04499AA 8 47866583_ 02 12 2015 41 2 41 200 6 ...

Page 492: ...eeve and spool The outer thin bearing race can sometimes stick in the housing therefore check that it has come out GNIL14TR04501AA 10 12 Press out the cross pin Use the special screw from the end cover GNIL14TR04502AA 11 NOTE A small mark has been made with pumice stone on both spool and sleeve close to one of the slots for the neu tral position springs see figure If the mark is not visible rememb...

Page 493: ... GNIL14TR04504AA 13 14 Press the neutral position springs out of their slots in the spool GNIL14TR04505AA 14 15 Remove dust seal and O ring kin ring roto glyd GNIL14TR04506AA 15 16 The steering unit OSPB is now completely dismantled GNIL14TR04507AA 16 47866583_ 02 12 2015 41 2 41 200 8 ...

Page 494: ...Steering Hydraulic control components Power steering control valve Cleaning Clean all parts carefully in Shellsoi K or something sim ilar 47866583_ 02 12 2015 41 2 41 200 9 ...

Page 495: ...Steering Hydraulic control components Power steering control valve Inspect Replace all seals and washers Check all parts care fully Make the necessary replacements 47866583_ 02 12 2015 41 2 41 200 10 ...

Page 496: ...Steering Hydraulic control components Power steering control valve Lubricate Before assembly lubricate all parts with hydraulic oil 47866583_ 02 12 2015 41 2 41 200 11 ...

Page 497: ...us injury W0208A CAUTION Pinch hazard Always use suitable tools to align mating parts DO NOT use your hand or fingers Failure to comply could result in minor or moderate injury C0044A 1 Place the two flat neutral position springs in the slot Place the curved springs between the flat ones and press them into the place GNIL14TR04508AA 1 2 Line up the spring set GNIL14TR04509AA 2 3 Guide the spool in...

Page 498: ...oles in the sleeve in the end of the spool sleeve opposite to the end with speing slots Place the slots and holes opposite each other so that parts of the holes in the sleeve are visible through the slots in the spool GNIL14TR04512AA 5 5 Press the springs together and push the neutral posi tion springs into place in the sleeve GNIL14TR04513AA 6 6 Line up the springs and centre them GNIL14TR04514AA...

Page 499: ...the sleeve NOTE The ring should be able to move free of the springs GNIL14TR04515AA 8 8 Fit the cross pin into the spool sleeve GNIL14TR04516AA 9 9 Fit bearing races and needle bearing as shown on be low drawing GNIL14TR04517AA 10 47866583_ 02 12 2015 41 2 41 200 14 ...

Page 500: ...ace 4 Spool 5 Sleeve GNIL14TR04518AB 11 The inside chamfer on the inner bearing race must face the inner spool Installation of O ring 1 Turn the steering unit until the bore is horizontal in po sition Guide the outer part of the assembly tool into the bore for the spool sleeve GNIL14TR04519AA 12 47866583_ 02 12 2015 41 2 41 200 15 ...

Page 501: ... the bottom of the steering unit housing and guide the inner part of the tool right to the bottom GNIL14TR04521AA 14 4 Press and turn the O ring kin ring into position in the housing GNIL14TR04522AA 15 5 Draw the inner and outer parts of the assembly tool out of the steering unit bore leaving the guide from the inner part in the bore GNIL14TR04523AA 16 47866583_ 02 12 2015 41 2 41 200 16 ...

Page 502: ...0044A 1 Lubricate the lip seal with hydraulic oil and place it on the assembly tool GNIL14TR04524AA 17 2 Guide the assembly tool right to the bottom GNIL14TR04525AA 18 3 Press and turn the lip seal into place in the housing GNIL14TR04526AA 19 4 With a light turning movement guide the spool and sleeve into the bore NOTE Fit the spool set holding the cross pin horizontal GNIL14TR04527AA 20 47866583_...

Page 503: ...rn the steering unit until the bore is vertical again Put the check valve ball into the hole indicated by the arrow GNIL14TR04529AA 22 7 Screw the threaded bush lightly into the check valve bore The top of the bush must lie just below the sur face of the housing GNIL14TR04530AA 23 8 Place a ball in the two holes 1 GNIL14TR04531AB 24 47866583_ 02 12 2015 41 2 41 200 18 ...

Page 504: ...oil approximately vis cosity 500 mm2 s at 20 C 68 F GNIL14TR04532AA 26 11 Place the distributor plate so that the channel holes match the holes in the housing GNIL14TR04533AA 27 12 Guide the cardan shaft down into the bore so that the slot is parallel with the connection flange GNIL14TR04534AA 28 47866583_ 02 12 2015 41 2 41 200 19 ...

Page 505: ...and place them in the two grooves in the gear rim Fit the gearwheel and rim on the cardan shaft GNIL14TR04536AA 30 NOTE Fit the gear wheel rotor and cardon shaft so that a tooth base in the rotor is positioned in relation to the shaft slot as shown Turn the gear rim so that the seven through holes match the holes in the housing GNIL14TR04537AA 31 15 Fit the spacer if any GNIL14TR04539AA 32 4786658...

Page 506: ...e 1 GNIL14TR04541AB 34 18 Fit the six screws with washers and insert them Cross tighten all the screws and the rolled pin with a torque of 3 0 0 6 daNm The steering motor can now be function tested GNIL14TR04542AA 35 19 Fit the dust seal ring in the housing using suitable tool and a plastic hammer GNIL14TR04543AA 36 47866583_ 02 12 2015 41 2 41 200 21 ...

Page 507: ...Steering Hydraulic control components 20 Press the plastic plugs into the connection ports NOTE Do not use a hammer GNIL14TR04544AA 37 47866583_ 02 12 2015 41 2 41 200 22 ...

Page 508: ...Steering Hydraulic control components Power steering control valve Install For installation follow the removal process in reverse 47866583_ 02 12 2015 41 2 41 200 23 ...

Page 509: ... As shown in Fig 1 4 Start tractor and set engine speed to 1450 RPM Turn steering wheel to the left with a pull of approximately 22 N 5 lb and observe the pressure reading NOTE The use of a force greater than 22 N 5 lb at the rim of the steering wheel may lead to slightly inaccurate read ings due to the pumping action of the hydrostatic steering motor If the steering test was satisfactory but pres...

Page 510: ...in Figure 1 3 Cap all connections to steering cylinder 4 Connect the return hose normally If required connect with extra hose and suitable adopter 5 Start the engine and idle between 1450 1500 RPM Run the tractor until the transmission oil reaches normal working temperature 6 With the engine running turn the steering motor shaft to obtain full lock The pressure gauge reading should read 10300 kPa ...

Page 511: ...control valve Cleaning 9 Power steering control valve Disassemble 5 Power steering control valve Inspect 10 Power steering control valve Install 23 Power steering control valve Lubricate 11 Power steering control valve Remove 4 Steering circuit relief valve Adjust 25 Steering circuit relief valve Pressure test 24 47866583_ 02 12 2015 41 2 41 200 26 ...

Page 512: ...Steering 41 Pump 206 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 41 3 41 206 1 ...

Page 513: ...Contents Steering 41 Pump 206 TECHNICAL DATA Power steering pump General specification 3 SERVICE Pump Remove 4 Install 5 47866583_ 02 12 2015 41 3 41 206 2 ...

Page 514: ...ion On the right hand side of the engine Mounting Fitted on engine timing case and driven by timing gears Make Rexroth Bosch Group Drive Engine timing gears Rotation seen from the free end of the drive shaft Anti clockwise Displacement 8 cm per revolution Max rotational speed 3300 RPM Flow at 1500 RPM 210 bar 10 56 L min 47866583_ 02 12 2015 41 3 41 206 3 ...

Page 515: ...Steering Pump Pump Remove Steering pump is in tandem with the hydraulic pump See Fixed displacement pump Remove 35 104 for steering pump removal 47866583_ 02 12 2015 41 3 41 206 4 ...

Page 516: ...Steering Pump Pump Install For installation follow the removal process in reverse 47866583_ 02 12 2015 41 3 41 206 5 ...

Page 517: ...Index Steering 41 Pump 206 Power steering pump General specification 3 Pump Install 5 Pump Remove 4 47866583_ 02 12 2015 41 3 41 206 6 ...

Page 518: ...Steering 41 Cylinders 216 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 41 4 41 216 1 ...

Page 519: ...Contents Steering 41 Cylinders 216 SERVICE Steering cylinder Remove 2WD 3 Overhaul 4 Install 9 47866583_ 02 12 2015 41 4 41 216 2 ...

Page 520: ...nds and remove hose clamps NOTE Position of flexible pipes and orientation of connec tors must be the same upon re assembly 3 Remove the nut securing the cylinder rod ball joint to the steering arm and separate the joint 1 4 Remove the nut securing the steering cylinder on front axle beam 5 Remove the steering cylinder from the tractor and re trieve washer spacer and bolt pivot pin 47866583_ 02 12...

Page 521: ...Nut 4 Lock nut 8 Seal kit 1 Fix the body taking care not to scratch it 2 Push the rod to the end of the stroke in the welded side 3 Use the seeger clamp to remove the head seeger 4 Use the head bell and the plastic hammer to push the head inside the body 20 00 30 00 mm 0 79 1 18 in GNIL14TR04548AA 2 47866583_ 02 12 2015 41 4 41 216 4 ...

Page 522: ...e rod by pulling Seal on the piston could require energetic action Clamp the rod paying special attention to not scratch its surface 8 Remove with the screw driver piston seal and O ring under the seal GNIL14TR04549AA 4 9 Throw away used seal and open the seal kit and clean the piston GNIL14TR04550AA 5 10 Apply piston seal mounting bell against piston and in sert the O ring having it slipping on t...

Page 523: ...NIL14TR04552AA 7 2 Insert the external ring of the piston seal over the O ring just mounted in this way Position the ring over the bell take the pushing tool and overpass with it in the piston The seal will fit its groove automatically GNIL14TR04553AA 8 3 Calibrate the seal with the appropriate tool NOTICE Use the screwdriver with care avoiding scratches on seal grooves GNIL14TR04554AA 9 4 Remove ...

Page 524: ...ted to retain oil GNIL14TR04557AA 12 7 Mount manually the wiper taking care about lip orien tation and the static seal external GNIL14TR04558AA 13 8 Draw the inner and outer parts of the assembly tool out of the steering unit bore leaving the guide from the inner part in the bore 9 Lubricate the lip seal with hydraulic oil and place it on the assembly tool GNIL14TR04559AA 14 47866583_ 02 12 2015 4...

Page 525: ...w self locking nut at torque Nm Grease every seal on body head and piston Grease the internal wall of body 20 00 30 00 mm 0 79 1 18 in entrance zone GNIL14TR04560AA 15 2 Insert the assembled rod Taking care to not damage piston seal Hammer the rod to end of stroke Unscrew the rod bell and screw on the other side GNIL14TR04561AA 16 3 Insert the head manually up to 20 00 30 00 mm 0 79 1 18 in inside...

Page 526: ...Steering Cylinders Steering cylinder Install For installation follow the removal process in reverse order 47866583_ 02 12 2015 41 4 41 216 9 ...

Page 527: ...Index Steering 41 Cylinders 216 Steering cylinder Install 9 Steering cylinder Overhaul 4 Steering cylinder Remove 2WD 3 47866583_ 02 12 2015 41 4 41 216 10 ...

Page 528: ...47866583_ 02 12 2015 41 4 41 216 11 ...

Page 529: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 530: ...SERVICE MANUAL Wheels Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 44 ...

Page 531: ...Contents Wheels 44 44 511 Front wheels 44 1 44 520 Rear wheels 44 2 47866583_ 02 12 2015 44 ...

Page 532: ...Wheels 44 Front wheels 511 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 44 1 44 511 1 ...

Page 533: ...Contents Wheels 44 Front wheels 511 SERVICE Front wheels Test 2WD 3 Toe in adjust 2WD 4 Adjust 5 Adjust 7 47866583_ 02 12 2015 44 1 44 511 2 ...

Page 534: ...n the tractor moves along a straight line wheels should be tilted by 2 relative to the ground Check the front wheel camber that corresponds to a difference X of approximately 15 0 mm 0 6 in between the rim edges GNIL14TR04457AB 1 47866583_ 02 12 2015 44 1 44 511 3 ...

Page 535: ... are parallel to the tractor centre line 4 Measure the distance B between the wheel inner rims at hub height at the front of the wheels 5 Measure the distance between the wheel inner rims at hub height at the rear of the wheels The measurement taken should be the same as B or greater by up to 5 00 mm 0 20 in max GNIL14TR04458AB 1 6 If it is necessary to adjust the front wheel toe in pro ceed as fo...

Page 536: ...ble and consists of a central hol low tube with a solid extendible section at each end The left hand end of the tie rod has a number of notches 1 at 50 mm 1 97 in intervals A locating bolt 2 passes through a clamp and one of the notches in the solid section and locks the tie rod assembly at the de sired length Additionally the right hand end of the tie rod is threaded 3 to provide fine adjustment ...

Page 537: ...nt wheel bolt torque 320 0 N m 236 0 lb ft NOTE Re check all torque settings after 50 h of operation Tie rod 5 The tie rod located behind the axle must be disengaged to permit adjustment of the axle The tie rod is tele scopic and consists of a central hollow tube with a solid extendible section at each end Remove the locating bolt 1 from both ends of the tie rod The position for the setting of the...

Page 538: ...ied torque value and at the recommended intervals Failure to comply could result in death or serious injury W0346B Tread setting 4WD Front Axle 4WD Tread Setting 9 5 24 A NA B NA C NA D Standard 1558 0 mm 61 3 in E 1522 0 mm 59 9 in F 1630 0 mm 64 2 in G 1650 0 mm 65 0 in H 1758 0 mm 69 2 in 4WD Front Axle R4 12 5 80 18 Front 1532 mm 47866583_ 02 12 2015 44 1 44 511 7 ...

Page 539: ...Wheels Front wheels 1 Front wheel bolt torque 192 0 N m 141 6 lb ft 76096164N 85X23 1 47866583_ 02 12 2015 44 1 44 511 8 ...

Page 540: ...Index Wheels 44 Front wheels 511 Front wheels Adjust 5 Front wheels Adjust 7 Front wheels Test 2WD 3 Front wheels Toe in adjust 2WD 4 47866583_ 02 12 2015 44 1 44 511 9 ...

Page 541: ...47866583_ 02 12 2015 44 1 44 511 10 ...

Page 542: ...Wheels 44 Rear wheels 520 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 44 2 44 520 1 ...

Page 543: ...Contents Wheels 44 Rear wheels 520 SERVICE Rear wheel Adjust 3 47866583_ 02 12 2015 44 2 44 520 2 ...

Page 544: ...center of the tires are nominal and may vary by as much as 13 mm 0 5 in 2 When installing or adjusting a wheel torque the bolts to the following values Recheck after driving the tractor for 1 hour and 8 hours operation and thereafter at the 50 hour intervals NOTICE When interchanging left and right wheel assem blies ensure the V of the tire tread remains pointing in the direction of forward travel...

Page 545: ... 4WD 4WD 13 6 R 28 14 9 R 28 R4 18 4X24 A N A N A N A B N A N A 1438 0 mm 56 6 in C N A N A N A D 1336 0 mm 52 6 in 1336 0 mm 52 6 in N A E 1420 0 mm 56 in 1420 0 mm 56 in N A F 1534 0 mm 60 4 in 1534 0 mm 60 4 in N A G 1623 0 mm 64 in 1623 0 mm 64 in N A H 1737 0 mm 68 4 in 1737 0 mm 68 4 in N A 47866583_ 02 12 2015 44 2 44 520 4 ...

Page 546: ...Index Wheels 44 Rear wheels 520 Rear wheel Adjust 3 47866583_ 02 12 2015 44 2 44 520 5 ...

Page 547: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 548: ...SERVICE MANUAL Electrical systems Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 ...

Page 549: ...ol system 55 3 55 100 Harnesses and connectors 55 4 55 201 Engine starting system 55 5 55 301 Alternator 55 6 55 302 Battery 55 7 55 404 External lighting 55 8 55 405 External lighting switches and relays 55 9 55 408 Warning indicators alarms and instruments 55 10 55 512 Cab controls 55 11 55 DTC FAULT CODES 55 12 47866583_ 02 12 2015 55 ...

Page 550: ...Electrical systems 55 Electrical system 000 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 1 55 000 1 ...

Page 551: ...al systems 55 Electrical system 000 TECHNICAL DATA Electrical system General specification 3 FUNCTIONAL DATA Electrical system Overview 4 DIAGNOSTIC Electrical system Troubleshooting 5 47866583_ 02 12 2015 55 1 55 000 2 ...

Page 552: ...75 A Battery type 12 V Negative ground BCI group 47 CCA 600 850 Cold start aid Yes Starter motor type Solenoid operated Starter kw hp rating 2 0 kW 2 7 Hp Bulb rating and type Head light 12 V 55 65 W Turn signal 12 V 21 W Tail light 12 V 21 W No 1157 Parking lamp 12 V 5 W Work lamp 12 V 50 W Enhanced turn lamps red 12 V 21 W 47866583_ 02 12 2015 55 1 55 000 3 ...

Page 553: ...ough them This opens circuit and protects the wiring from burning This can occur in the event of a short circuit or by connecting equipment which demands a current greater than the circuit designed to carry The fuse is specially designed and in the event of failure a new fuse of the same rating should be fitted NOTICE The fuse should never be repaired or replaced by a fuse of a higher rating If th...

Page 554: ...uit and repair as necessary Insufficient or no battery charge hard starting or dim indicator light Battery charge less than 75 Test battery Charge add water or replace as necessary Fan belt slipping Check fan belt tension adjust as neces sary Loose wiring connections Check wiring connections for charge cir cuit repair as necessary Continuity fault in external wiring Check wiring harness and repair...

Page 555: ...Index Electrical systems 55 Electrical system 000 Electrical system General specification 3 Electrical system Overview 4 Electrical system Troubleshooting 5 47866583_ 02 12 2015 55 1 55 000 6 ...

Page 556: ...Electrical systems 55 Transmission control system 024 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 2 55 024 1 ...

Page 557: ...ctrical systems 55 Transmission control system 024 SERVICE Transmission control system Ground speed control Test Transmission range safety switch 3 See content for specific models 47866583_ 02 12 2015 55 2 55 024 2 ...

Page 558: ...ger in the extended position A there will be electrical continuity across the terminal leads 1 If continuity does not exist while the switch is in the Extended position the switch is defective and needs replaced 30002201 1 Retracted position not shown 1 With the switch plunger in retracted position conti nuity will not exist between the terminal leads 2 If continuity exits while the switch is in t...

Page 559: ...Index Electrical systems 55 Transmission control system 024 Ground speed control Test Transmission range safety switch 3 See content for specific models 47866583_ 02 12 2015 55 2 55 024 4 ...

Page 560: ...Electrical systems 55 Rear Power Take Off PTO control system 048 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 3 55 048 1 ...

Page 561: ...s 55 Rear Power Take Off PTO control system 048 FUNCTIONAL DATA Power Take Off PTO speed sensor Static description PTO Safety switch 3 SERVICE Power Take Off PTO speed sensor Remove 4 Install 5 47866583_ 02 12 2015 55 3 55 048 2 ...

Page 562: ...ble pole single throw style switch located on the PTO control lever quadrant The switch has a rubber booted push button actuator and is activated by the PTO clutch lever When the PTO clutch lever is in the OFF position the switch button is OUT when the PTO clutch is engaged the switch button is in the IN position 86072157 1 47866583_ 02 12 2015 55 3 55 048 3 ...

Page 563: ...e of the tractor See Fenders and guards Remove 90 116 2 Loosen the bolts 1 GNIL14TR00840AA 1 3 Lift the plate 1 access the wire connector 4 Disconnect the wiring 2 GNIL14TR00838AA 2 5 Loosen the bolts 1 and remove the sensor assem bly 6 Loosen the nut 2 and remove the PTO sensor GNIL14TR00839AA 3 47866583_ 02 12 2015 55 3 55 048 4 ...

Page 564: ... Power Take Off PTO speed sensor Install 1 Connect the wiring 1 GNIL14TR00838AA 1 2 Fit the PTO sensor and tighten the nut 1 3 Tighten the bolts 2 GNIL14TR00839AA 2 4 Install the plate 1 Tighten the bolts 2 GNIL14TR00840AA 3 47866583_ 02 12 2015 55 3 55 048 5 ...

Page 565: ...ear Power Take Off PTO control system 048 Power Take Off PTO speed sensor Install 5 Power Take Off PTO speed sensor Remove 4 Power Take Off PTO speed sensor Static description PTO Safety switch 3 47866583_ 02 12 2015 55 3 55 048 6 ...

Page 566: ...Electrical systems 55 Harnesses and connectors 100 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 4 55 100 1 ...

Page 567: ...IGHTS 20 Electrical schematic sheet 11 SH11 REAR LIGHTS 22 Electrical schematic sheet 12 SH12 DIAGONESTIC TRAILER SOCKET 24 Electrical schematic sheet 01 Power distribution and glow plugs engine schematics 26 Electrical schematic sheet 02 Engine Control Unit ECU power and after treatment system engine schematics 28 Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 3...

Page 568: ...Connectors X 9120 to X 9129 85 Electrical components Fuse description 88 Voltage source description 90 Relay description 91 Motor description 93 Switch description 94 SERVICE Wiring harnesses Repair 95 DIAGNOSTIC Wiring harnesses Troubleshooting Safety start circuit Operator present 97 Troubleshooting Safety start circuit Operator not present 97 Troubleshooting Safe Operation Operator Present 98 T...

Page 569: ...RTER SWITCH Fuse F 010 HEATER Fuse F 011 LOADER Fuse F 012 ECU SAFETY START Fuse F 013 DUMMY1 Fuse F 014 DUMMY2 Relay K 001 ECU POWER Relay K 002 CRANKING RELAY Relay K 013 FRONT LOADER Relay K 014 HEATER Connector X 006 X 006 ECU RELAY Connector X 009 X 009 CRANKING RELAY Connector X 027 X 027 PRE HEATER Connector X 028 X 028 FRONT LOADER Connector X 404A X 404A ENGINE MAIN INTERCONNECT Connector...

Page 570: ...Electrical systems Harnesses and connectors SHT_2 1 47866583_ 02 12 2015 55 4 55 100 5 ...

Page 571: ...STARTER MOTOR Connector X 001A X 001A Connector X 001B X 001B Connector X 004A X 004A Connector X 009 X 009 CRANKING RELAY Connector X 015 X 015 TO MEGA FUSE Connector X 017 X 017 FROM MEGA FUSE Connector X 206 X 206 TO STARTER MOTOR Connector X 209 X 209 ALTERNATOR D Connector X 404A X 404A ENGINE MAIN INTERCONNECT Connector X 404B X 404B MAIN ENGINE INTERCONNECT Connector X 712 X 712 ALTERNATOR ...

Page 572: ...Electrical systems Harnesses and connectors SHT_3 1 47866583_ 02 12 2015 55 4 55 100 7 ...

Page 573: ...lay K 006 HIGH BEAM Relay K 007 LOW BEAM Relay K 008 PTO SAFETY START Relay K 009 STOP LIGHT Relay K 010 ENGINE SHUT OFF Relay K 011 SAFETY RUN Relay K 012 CRANK PROTECTION Connector X 001 X 001 Connector X 004 X 004 DIODE Connector X 009 X 009 CRANKING RELAY Connector X 404A X 404A ENGINE MAIN INTERCONNECT Connector X 404B X 404B MAIN ENGINE INTERCONNECT Connector X 406A X 406A TO ENGINE HARNESS ...

Page 574: ...Electrical systems Harnesses and connectors SHT_4 1 47866583_ 02 12 2015 55 4 55 100 9 ...

Page 575: ... SH05 GROUNDING SYSTEM Type Component Connector Link Description Fuse F 002 F 002 GEP FUSE BOX Connector X 002A X 002A GROUND TERMINAL Connector X 002B X 002B FENDER GROUND Connector X 002C X 002C MAIN HARNESS GND Connector X 002D X 002D ECU ENGINE GROUND 47866583_ 02 12 2015 55 4 55 100 10 ...

Page 576: ...Electrical systems Harnesses and connectors SHT_5 1 47866583_ 02 12 2015 55 4 55 100 11 ...

Page 577: ...H Connector X 005 X 005 LIGHT SWITCH Connector X 007 X 007 HORN SWITCH CN1 Connector X 008 X 008 HORN SWITCH CN2 Connector X 011 X 011 TURN FLASHER Connector X 012 X 012 TURN SWITCH Connector X 013 X 013 WORK LAMP Connector X 400A X 400A MAIN FENDER INTERCONNECT Connector X 400B X 400B FENDER MAIN INTERCONNECT Connector X 404A X 404A ENGINE MAIN INTERCONNECT Connector X 404B X 404B MAIN ENGINE INT...

Page 578: ...Electrical systems Harnesses and connectors SHT_6 1 47866583_ 02 12 2015 55 4 55 100 13 ...

Page 579: ...ector X 022 X 022 FOOT THROTTLE Connector X 023 X 023 HAND THROTTLE Connector X 050 X 050 INSTRUMENT CLUSTER CN 1 Connector X 051 X 051 INSTRUMENT CLUSTER CN 2 Connector X 105 X 105 OPRATOR SAFETY MODULE Connector X 211 X 211 AIR CLOG SWITCH Connector X 213 X 213 AIR CLOG SWITCH Connector X 402A X 402A FENDER MAIN INTERCONNECT Connector X 402B X 402B MAIN FENDER INTERCONNECT Connector X 404A X 404...

Page 580: ...Electrical systems Harnesses and connectors SHT_7 1 47866583_ 02 12 2015 55 4 55 100 15 ...

Page 581: ...X 027 PRE HEATER Connector X 101 X 101 GCU Connector X 201 X 201 ECU VEHICLE Connector X 207 X 207 TO ENGINE GLOW PLUGS Connector X 212 X 212 LAMBDA SENSOR Connector X 214 X 214 INLET DOC TEMP SENSOR Connector X 215 X 215 OUTLET POC TEMP SENSOR Connector X 404A X 404A ENGINE MAIN INTERCONNECT Connector X 404B X 404B MAIN ENGINE INTERCONNECT Connector X 406A X 406A TO ENGINE HARNESS Connector X 406...

Page 582: ...Electrical systems Harnesses and connectors SHT_8 1 47866583_ 02 12 2015 55 4 55 100 17 ...

Page 583: ...ctor X 400B X 400B FENDER MAIN INTERCONNECT Connector X 402A X 402A FENDER MAIN INTERCONNECT Connector X 402B X 402B MAIN FENDER INTERCONNECT Connector X 404A X 404A ENGINE MAIN INTERCONNECT Connector X 404B X 404B MAIN ENGINE INTERCONNECT Connector X 406A X 406A TO ENGINE HARNESS Connector X 406B X 406B TO MAIN HARNESS Connector X 502 X 502 PTO SWITCH Connector X 503 X 503 NEUTRAL SAFETY SWITCH C...

Page 584: ...Electrical systems Harnesses and connectors SHT_9 1 47866583_ 02 12 2015 55 4 55 100 19 ...

Page 585: ...ription Connector X 001 X 001 Connector X 216A X 216A ENGINE INTERCONNECT Connector X 216B X 216B HEADLAMP INTERCONNECT Connector X 301 X 301 HEADLAMP RH Connector X 302 X 302 HEADLAMP LH Connector X 303 X 303 WORKLAMP RH Connector X 304 X 304 WORKLAMP LH Connector X 305 X 305 HORN Connector X 306 X 306 HORN GND 47866583_ 02 12 2015 55 4 55 100 20 ...

Page 586: ...Electrical systems Harnesses and connectors SHT_10 1 47866583_ 02 12 2015 55 4 55 100 21 ...

Page 587: ...X 400A X 400A MAIN FENDER INTERCONNECT Connector X 400B X 400B FENDER MAIN INTERCONNECT Connector X 404A X 404A ENGINE MAIN INTERCONNECT Connector X 404B X 404B MAIN ENGINE INTERCONNECT Connector X 516 X 516 BECON LAMP Connector X 517 X 517 IMPLEMENT LAMP Connector X 518 X 518 LICENCE LAMP Connector X 612 X 612 ROPE LAMP RH Connector X 613 X 613 ROPE LAMP LH 47866583_ 02 12 2015 55 4 55 100 22 ...

Page 588: ...Electrical systems Harnesses and connectors SHT_11 1 47866583_ 02 12 2015 55 4 55 100 23 ...

Page 589: ...r X 053 X 053 DIAGONESTIC SOCKET Connector X 404A X 404A ENGINE MAIN INTERCONNECT Connector X 404B X 404B MAIN ENGINE INTERCONNECT Connector X 602A X 602A TO TRAILER HARNESS Connector X 602B X 602B TO FENDER HARNESS Connector X 702A X 702A TO DIAGONESTIC SOCKET Connector X 702B X 702B TO MAIN HARNESS Connector X 902 X 902 TRAILER SOCKET 47866583_ 02 12 2015 55 4 55 100 24 ...

Page 590: ...Electrical systems Harnesses and connectors SHT_12 1 47866583_ 02 12 2015 55 4 55 100 25 ...

Page 591: ...bution and glow plugs engine schematics Component Identifier Description K 9104 Starter control relay R 9001 Cylinder 1 glow plug R 9002 Cylinder 2 glow plug R 9003 Cylinder 3 glow plug Z 9101 Glow plug control unit 1 to machine starting circuit see machine schematics 47866583_ 02 12 2015 55 4 55 100 26 ...

Page 592: ...Electrical systems Harnesses and connectors NHIL15ENG0123JA 1 47866583_ 02 12 2015 55 4 55 100 27 ...

Page 593: ... Control Unit ECU B 9123 Lambda Universal Heated Exhaust Gas Oxygen UHEGO sensor B 9126 Diesel Oxidation Catalyst DOC inlet temperature sensor B 9127 Particulate Matter PM catalyst intlet temperature sensor K 9102 Main relay K 9111 Engine shut off relay S 9102 Water in fuel switch 1 represents the potential vehicle control module present on the machine see machine schematics 47866583_ 02 12 2015 5...

Page 594: ...Electrical systems Harnesses and connectors NHIL15ENG0154JA 1 47866583_ 02 12 2015 55 4 55 100 29 ...

Page 595: ...d pressure and temperature sensor B 9002 Fuel temperature sensor B 9003 Coolant temperature sensor B 9004 Rail pressure sensor B 9007 Crankshaft sensor B 9017 Camshaft sensor S 9016 Oil pressure switch Y 9000 Fuel metering unit Y 9001 Cylinder 1 injector Bank 1 Injector 1 Y 9002 Cylinder 2 injector Bank 1 Injector 2 Y 9003 Cylinder 3 injector Bank 2 Injector 1 Z 9001 Throttle valve actuator 478665...

Page 596: ...Electrical systems Harnesses and connectors NHIL15ENG0155JA 1 47866583_ 02 12 2015 55 4 55 100 31 ...

Page 597: ...Electrical systems Harnesses and connectors 47866583_ 02 12 2015 55 4 55 100 32 ...

Page 598: ... 24 X 406B pin 7 TO MAIN HARNESS 053 053 YE 0 75 25 SP 019 P X 009S 009S BK 0 5 SHEET 04 26 SP 025 P X 031A 031A RD BL 1 5 SHEET 02 27 SP 017 P X 009K 009K BK 0 5 28 SP 097 P X 095 095 GY 0 75 33 X 216B pin 5 HEADLAMP INTERCONNECT 032 WORK LAMP OR 1 5 34 X 406B pin 3 TO MAIN HARNESS 091 091 PRP 0 5 35 X 404B pin 4 MAIN ENGINE INTERCONNECT 108 108 VT 0 75 36 SP 096 P X 096B 096B GY 0 5 37 SP 019 P ...

Page 599: ...Wire Description Color Size Frame PIN1 X 001B pin PIN1 002 BATTERY CABLE GROUND BK 40 0 SHEET 03 X 002B FENDER GROUND 84153309 Male 84153309 2 84153309 Pin From Wire Description Color Size Frame 1 SP 010 P X 010 FENDER GROUND BK 6 0 SHEET 05 X 002C MAIN HARNESS GND 84153309 Male 84153309 3 84153309 Pin From Wire Description Color Size Frame 1 SP 005 P X 005 MAIN HARNESS GND BK 6 0 SHEET 05 4786658...

Page 600: ...03 IGNITION SWITCH S 001 84479009 Female 84479009 5 84479009 Pin From Wire Description Color Size Frame 2 SP 106 P X 021A 021A RD 3 0 3 X 406A P 2 065 065 YE 0 75 4 SP 101 P X 089A 089A RD GN 2 5 SHEET 06 X 004 DIODE 84179574 Female 84179574 6 84179574 Pin From Wire Description Color Size Frame 1 SP 096 P X 096A 096A GY 0 75 2 SP 097 P X 095A 095A GY 0 75 SHEET 04 47866583_ 02 12 2015 55 4 55 100 ...

Page 601: ...03 X 005 LIGHT SWITCH 84179574 Female 84179574 7 84179574 Pin From Wire Description Color Size Frame 1 SP 060 P X 060 060 BL YE 0 75 2 SP 029 P X 029C 029C GN OR 1 5 2 HORN LIGHT TURN SWITCH P PWR1 WIRE235 WIRE235 3 X 406A P 10 073 073 GN YE 0 75 4 SP 058 P X 058 058 BL BK 0 75 SHEET 06 X 006 ECU RELAY 47781083 Male 47781083 8 47781083 47866583_ 02 12 2015 55 4 55 100 36 ...

Page 602: ...Wire Description Color Size Frame 1 SP 029 P X 029B 029B GN OR 0 75 SHEET 06 X 008 HORN SWITCH CN2 87581782 Female 87581782 10 87581782 Pin From Wire Description Color Size Frame 1 X 406A P 12 071 071 YE BL 0 75 SHEET 06 X 009 CRANKING RELAY 47781083 Male 47781083 11 47781083 47866583_ 02 12 2015 55 4 55 100 37 ...

Page 603: ...From Wire Description Color Size Frame 1 F 003 P 1 MINI FUSER 030 TURN STOP LAMP LG 0 75 2 X 011 pin 8 TURN FLASHER 061 061 LG BL 0 75 3 X 011 pin 7 TURN FLASHER 062 062 LG WH 0 75 SHEET 06 X 013 WORK LAMP 84179576 Female 84179576 3 84179576 Pin From Wire Description Color Size Frame 4 SP 029 P X 029D 029D GN OR 1 0 6 SP 090 P X 090A 090A VT 0 75 SHEET 06 47866583_ 02 12 2015 55 4 55 100 38 ...

Page 604: ...MAIN HARNESS 034 034 BL 0 75 3 SP 159 P X 159B 159B PK WH 0 5 SHEET 09 5 SP 009 P X 009T 009T BK 0 5 SHEET 05 6 SP 085 P X 084 084 PK 0 75 SHEET 02 X 015 TO MEGA FUSE F 001 84488487 Male 84488487 5 84488487 Pin From Wire Description Color Size Frame 1 X 901 Male pin 1 ALTERNATOR B 008 008 RD 8 0 SHEET 03 X 016 BRAKE SWITCH 84182898 Female 84182898 6 84182898 47866583_ 02 12 2015 55 4 55 100 39 ...

Page 605: ...cription Color Size Frame 1 SP 007 P X 007 007 RD 8 0 SHEET 03 X 018 HOME ENTER SWITCH S 007 87745329 Female 87745329 8 87745329 Pin From Wire Description Color Size Frame 1 X 050 Female pin 20 INSTRUMENT CLUSTER CN 1 038 NAVIGATION SW ENTER YE GN 0 75 2 SP 006 P X 005E 005E BK 0 75 3 SP 006 P X 005F 005F BK 0 75 4 X 050 Female pin 21 INSTRUMENT CLUSTER CN 1 039 NAVIGATION SW HOME YE BL 0 75 SHEET...

Page 606: ... and connectors X 019 SWITCH LAMP H E S 007 84131048 Female 84131048 9 84131048 Pin From Wire Description Color Size Frame 1 SP 059 P X 134 134 BL BK 0 75 2 SP 006 P X 005G 005G BK 0 75 SHEET 07 47866583_ 02 12 2015 55 4 55 100 41 ...

Page 607: ...UMENT CLUSTER CN 1 040 NAVIGATION SW DWN PK BK 0 75 2 SP 006 P X 005H 005H BK 0 75 3 SP 006 P X 005K 005K BK 0 75 4 X 050 Female pin 23 INSTRUMENT CLUSTER CN 1 041 NAVIGATION SW UP BL BK 0 75 SHEET 07 X 021 SWITCH LAMP U D S 008 84131048 Female 84131048 2 84131048 Pin From Wire Description Color Size Frame 1 SP 059 P X 133 133 BL BK 0 75 2 SP 006 P X 005J 005J BK 0 75 SHEET 07 47866583_ 02 12 2015...

Page 608: ...1 0 5 X 402A P 6 143 FOOT THROTTLE YE GN 1 0 6 X 402A P 5 132 FOOT THROTTLE YE 1 0 SHEET 07 X 023 HAND THROTTLE 87694694 Male 87694694 4 87694694 Pin From Wire Description Color Size Frame 2 X 050 Female pin 8 INSTRUMENT CLUSTER CN 1 130 HAND THROTTLE YE 0 75 3 X 050 Female pin 12 INSTRUMENT CLUSTER CN 1 129 HAND THROTTLE SENS GROUND BK 0 75 4 X 051 pin 14 INSTRUMENT CLUSTER CN 2 128 HAND THROTTLE...

Page 609: ...e pin 3 PTO SWITCH 052 052 GN BK 0 75 2 X 402A P 4 093 093 YE 0 75 SHEET 09 X 026 SENSOR WATER IN FUEL 87709663 Female 87709663 6 87709663 Pin From Wire Description Color Size Frame 1 X 201 Female pin 88 ECU VEHICLE 044 044 YE 0 75 3 SP 018 P X 009H 009H BK 0 75 SHEET 08 X 027 PRE HEATER 84146680 Male 84146680 7 84146680 47866583_ 02 12 2015 55 4 55 100 44 ...

Page 610: ...connectors X 028 FRONT LOADER 82012083 Female 82012083 8 82012083 Pin From Wire Description Color Size Frame 1 F 002 Female P 33 GEP FUSE BOX 113 113 OR GN 1 0 2 SP 009 P X 009X 009X BK 1 0 SHEET 02 47866583_ 02 12 2015 55 4 55 100 45 ...

Page 611: ... 8 X 023 Male pin 2 HAND THROTTLE 130 HAND THROTTLE YE 0 75 9 SP 136 P X 136B 136B PK WH 0 5 12 X 023 Male pin 3 HAND THROTTLE 129 HAND THROTTLE SENS GROUND BK 0 75 17 X 011 pin 5 TURN FLASHER 118 118 LG BL 0 5 20 X 018 Female pin 1 HOME ENTER SWITCH 038 NAVIGATION SW ENTER YE GN 0 75 21 X 018 Female pin 4 HOME ENTER SWITCH 039 NAVIGATION SW HOME YE BL 0 75 22 X 020 Female pin 1 UP DOWN SWITCH 040...

Page 612: ... ADIC BK 1 0 SHEET 05 17 X 404A P 10 088 088 PK 0 75 SHEET 03 19 SP 058 P X 058B SIDE LIGHTS BL BK 0 75 20 SP 027 P X 027 027 RD GN 1 0 21 SP 131 P X 131B 131B OR 1 0 23 SP 090 P X 090B WORK LAMP VT 0 75 24 X 402B pin 11 MAIN FENDER INTERCONNECT 192 PTO SPEED SENSOR R B 1 0 26 SP 049 P X 049B NEUTRAL SAFETY ADIC RD GN 0 75 SHEET 07 X 053 DIAGONESTIC SOCKET 87516075 Male 87516075 3 87516075 Pin Fro...

Page 613: ...151 BR 0 75 4 SP 007 P X 007L 007L RD 6 0 5 X 201 Female pin 41 ECU VEHICLE 152 152 BK 3 0 7 X 207 Female pin B TO ENGINE GLOW PLUGS 153 153 GN 1 5 8 X 201 Female pin 52 ECU VEHICLE 154 154 GN 0 75 SHEET 08 X 105 OPRATOR SAFETY MODULE 84479170 Female 84479170 2 84479170 Pin From Wire Description Color Size Frame B X 406A P 8 064 064 BL 0 75 SHEET 07 C SP 005 P X 005L 005L BK 0 75 SHEET 05 E SP 124...

Page 614: ... 41 X 101 Female pin 5 GCU 152 152 BK 3 0 46 SP 002 P X 015E CAN HIGH YE 0 75 47 SP 001 P X 016E CAN LOW GN 0 75 52 X 101 Female pin 8 GCU 154 154 GN 0 75 53 F 002 Female P 48 GEP FUSE BOX 186 STARTER HIGH YE 0 75 54 SP 085 P X 085B 085B YE RD 0 75 55 X 406B pin 5 TO MAIN HARNESS 197 197 YE RD 0 75 SHEET 08 62 X 001 pin 40 046 046 BL 0 75 SHEET 04 63 X 212 Female pin 6 LAMBDA SENSOR 148 148 PK 0 7...

Page 615: ...07 TO ENGINE GLOW PLUGS 87693326 Female 87693326 3 87693326 Pin From Wire Description Color Size Frame B X 101 Female pin 7 GCU 153 153 GN 1 5 C X 101 Female pin 1 GCU 149 149 RD GN 1 5 SHEET 08 X 209 ALTERNATOR D G 002 84477008 Male 84477008 4 84477008 Pin From Wire Description Color Size Frame 1 X 404B pin 9 MAIN ENGINE INTERCONNECT 087 087 BR 0 5 SHEET 03 47866583_ 02 12 2015 55 4 55 100 50 ...

Page 616: ...LAMBDA SENSOR 84301132 Female 84301132 2 84301132 Pin From Wire Description Color Size Frame 1 X 201 Female pin 64 ECU VEHICLE 144 144 OR 0 75 2 X 201 Female pin 85 ECU VEHICLE 145 145 GN 0 75 3 X 201 Female pin 7 ECU VEHICLE 146 146 GN 1 0 4 F 002 P 7 GEP FUSE BOX 014 014 RD GN 1 0 5 X 201 Female pin 86 ECU VEHICLE 147 147 YE 0 75 6 X 201 Female pin 63 ECU VEHICLE 148 148 PK 0 75 SHEET 08 4786658...

Page 617: ...SENSOR BL RD 0 5 SHEET 07 X 214 INLET DOC TEMP SENSOR 87709793 Female 87709793 4 87709793 Pin From Wire Description Color Size Frame 1 X 201 Female pin 80 ECU VEHICLE 173 173 BL BK 0 75 SHEET 08 X 215 OUTLET POC TEMP SENSOR 87709793 Female 87709793 5 87709793 Pin From Wire Description Color Size Frame 2 X 201 Female pin 83 ECU VEHICLE 182 182 GN WH 0 75 SHEET 08 47866583_ 02 12 2015 55 4 55 100 52...

Page 618: ...ale 47405381 6 47405381 Pin From Wire Description Color Size Frame 1 X 001 pin 45 100 100 GN YE 1 5 SHEET 10 3 X 406B pin 12 TO MAIN HARNESS 072 072 YE BL 1 0 SHEET 06 4 SP 009 P X 009D 009D BK 1 0 SHEET 05 5 X 001 pin 33 032 WORK LAMP OR 1 5 SHEET 10 47866583_ 02 12 2015 55 4 55 100 53 ...

Page 619: ...102 P X 102B 102B GY 1 0 B SP 103 P X 103D 103D BK 1 0 C SP 104 P X 104B 104B GN YE 1 5 SHEET 10 X 302 HEADLAMP LH 87697641 Female 87697641 2 87697641 Pin From Wire Description Color Size Frame A SP 102 P X 102A 102A GY 1 0 B SP 103 P X 103A 103A BK 1 0 C SP 104 P X 104A 104A GN YE 1 5 SHEET 10 X 303 WORKLAMP RH 82003123 Female 82003123 3 82003123 47866583_ 02 12 2015 55 4 55 100 54 ...

Page 620: ...LH 82003123 Female 82003123 4 82003123 Pin From Wire Description Color Size Frame A SP 105 P X 105A 105A OR 1 5 B SP 103 P X 103B 103B BK 1 0 SHEET 10 X 305 HORN 87581782 Female 87581782 5 87581782 Pin From Wire Description Color Size Frame 1 X 216A Male P 3 106 106 YE BL 1 0 SHEET 10 X 306 HORN GND 87581782 Female 87581782 6 87581782 47866583_ 02 12 2015 55 4 55 100 55 ...

Page 621: ...Electrical systems Harnesses and connectors Pin From Wire Description Color Size Frame 1 SP 103 P X 103C 103C BK 1 0 SHEET 10 47866583_ 02 12 2015 55 4 55 100 56 ...

Page 622: ... Component diagram 40 X 400A MAIN FENDER INTERCONNECT 47731490 Female 47731490 1 47731490 X 402B MAIN FENDER INTERCONNECT 47731489 Female 47731489 2 47731489 X 404B MAIN ENGINE INTERCONNECT 47731487 Female 47731487 3 47731487 47866583_ 02 12 2015 55 4 55 100 57 ...

Page 623: ...Electrical systems Harnesses and connectors X 406B TO MAIN HARNESS 47731489 Female 47731489 4 47731489 47866583_ 02 12 2015 55 4 55 100 58 ...

Page 624: ... 1 SP 051 P X 051B 051B YE RD 0 75 2 SP 051 P X 051C 051C YE RD 0 75 3 X 025 Female pin 1 CLUTCH SWITCH 052 052 GN BK 0 75 4 X 400B P 11 155 155 VT 0 75 SHEET 09 X 503 NEUTRAL SAFETY SWITCH 47413294 Female 47413294 2 47413294 Pin From Wire Description Color Size Frame 1 SP 051 P X 051F 051F RD YE 1 0 2 X 400B P 10 097 097 RD GN 1 0 SHEET 09 47866583_ 02 12 2015 55 4 55 100 59 ...

Page 625: ... 079 079 RD 0 5 2 X 402A P 2 125 125 YE BK 0 5 SHEET 09 X 505 HI LOW SWITCH HI LOW SWITCH 82012083 Female 82012083 4 82012083 Pin From Wire Description Color Size Frame 1 X 506 Female pin 1 PTO CLUTCH SENSOR 190 190 YE GN 0 75 2 X 402A P 12 199 199 YE RD 0 75 SHEET 09 X 506 PTO CLUTCH SENSOR 82012083 Female 82012083 5 82012083 47866583_ 02 12 2015 55 4 55 100 60 ...

Page 626: ...ITCH 190 190 YE GN 0 75 2 X 402A P 3 196 196 VT 0 75 SHEET 09 X 507 FUEL SENDER UNIT 82012083 Female 82012083 6 82012083 Pin From Wire Description Color Size Frame 1 SP 140 P X 140B SENSOR GND BK 1 0 2 X 050 Female pin 2 INSTRUMENT CLUSTER CN 1 042 FUEL SENDER UNIT BL 0 75 SHEET 07 47866583_ 02 12 2015 55 4 55 100 61 ...

Page 627: ...re Description Color Size Frame 1 X 400B P 9 067 067 BL YE 0 5 2 SP 010 P X 010D 010D BK 0 5 SHEET 06 X 516 BECON LAMP 84182898 Female 84182898 2 84182898 Pin From Wire Description Color Size Frame 1 SP 024 P X 025 025 PK 0 75 2 SP 014 P X 164E 164E BK 0 75 SHEET 11 X 517 IMPLEMENT LAMP 84477032 Male 84477032 3 84477032 47866583_ 02 12 2015 55 4 55 100 62 ...

Page 628: ... 82000579 4 82000579 Pin From Wire Description Color Size Frame 1 SP 020 P X 169 169 RD WH 0 5 4 SP 014 P X 164C 164C BK 0 75 SHEET 11 X 519 SPEED SENSOR PTO 82865818 Female 82865818 5 82865818 Pin From Wire Description Color Size Frame 1 SP 051 P X 051E 051E OR 1 0 2 X 402A P 11 194 PTO SPEED SENSOR R B 1 0 SHEET 07 3 SP 010 P X 010C 010C BK 1 0 SHEET 05 47866583_ 02 12 2015 55 4 55 100 63 ...

Page 629: ...nectors Component diagram 52 X 520 LOADER JOYSTICK S 009 87715977 Female 87715977 1 87715977 Pin From Wire Description Color Size Frame 3 X 515B Male P 2 0002 0002 BK 0 5 4 X 515B Male P 1 0001 0001 BL YE 0 5 SHEET 06 47866583_ 02 12 2015 55 4 55 100 64 ...

Page 630: ... Color Size Frame 1 SP 163 P X 033 033 YE 0 75 SHEET 11 2 SP 010 P X 010A 010A BK 1 0 SHEET 05 3 SP 161 P X 035 035 OR 0 75 6 SP 020 P X 037 037 BR 0 75 SHEET 11 X 605 SEAT SWITCH 82012083 Female 82012083 2 82012083 Pin From Wire Description Color Size Frame 1 SP 051 P X 051D 051D YE RD 0 75 2 X 400B P 12 135 135 PK WH 0 5 SHEET 09 47866583_ 02 12 2015 55 4 55 100 65 ...

Page 631: ...ption Color Size Frame 3 SP 014 P X 164B 164B BK 0 75 4 SP 020 P X 172 172 BL BK 0 75 SHEET 11 X 613 ROPE LAMP LH 84182907 Male 84182907 2 84182907 Pin From Wire Description Color Size Frame 1 SP 163 P X 163 163 LG 0 5 2 X 400B P 7 111 111 GY 0 75 3 SP 014 P X 164A 164A BK 0 75 4 SP 020 P X 171 171 BL BK 0 75 SHEET 11 47866583_ 02 12 2015 55 4 55 100 66 ...

Page 632: ...Electrical systems Harnesses and connectors Wire connectors Component diagram 70 X 702A TO DIAGONESTIC SOCKET 47511905 Female 47511905 1 47511905 47866583_ 02 12 2015 55 4 55 100 67 ...

Page 633: ...488486 Pin From Wire Description Color Size Frame 1 X 713 Male pin 1 TO STARTER MOTOR 003 ALTERNATOR CABLE RD 16 0 SHEET 03 X 713 TO STARTER MOTOR 84488486 Male 84488486 2 84488486 Pin From Wire Description Color Size Frame 1 X 712 Male pin 1 ALTERNATOR B 003 ALTERNATOR CABLE RD 16 0 SHEET 03 47866583_ 02 12 2015 55 4 55 100 68 ...

Page 634: ...cription Color Size Frame 1 X 015 Male pin 1 TO MEGA FUSE 008 008 RD 8 0 SHEET 03 X 902 TRAILER SOCKET 84531642 Male 84531642 2 84531642 Pin From Wire Description Color Size Frame 1 X 602B Male P 2 201 201 WH 1 0 2 SP 011 P X 202A 202A BL 0 75 4 X 602B Male P 5 205 205 RD 0 75 6 SP 011 P X 202B 202B BL 0 75 SHEET 12 47866583_ 02 12 2015 55 4 55 100 69 ...

Page 635: ...lve Actuator TVA position sensor SHEET 03 A09 A10 EN 9101 5 V sensor supply Intake manifold pressure sensor A11 EN 9108 5 V sensor supply Rail pressure sensor SHEET 03 A12 A13 EN 9109 5 V sensor supply Camshaft speed sensor A14 EN 9111 Input signal Camshaft speed sensor A15 EN 9136 Switched voltage supply Fuel metering unit A16 EN 9125 HSD Bank 1 Injector 1 Cylinder 1 A17 EN 9129 HSD Bank 1 Inject...

Page 636: ...03 A39 A40 EN 9102 Input signal Intake manifold pressure sensor A41 EN 9107 Input signal Rail pressure sensor SHEET 03 A42 A43 A44 EN 9139 Input signal negative Crankshaft position sensor SHEET 03 A45 A46 A47 A48 EN 9130 LSD Bank 1 Injector 2 Cylinder 2 A49 EN 9134 H bridge Pulse Width Modulated supply TVA motor SHEET 03 A50 A51 A52 A53 EN 9099 Input signal TVA position sensor SHEET 03 A54 A55 EN ...

Page 637: ... Unit ECU reference ground pressure and temperature 2 EN 9104 ECU input signal temperature 3 EN 9101 ECU 5 V sensor supply pressure sensor 4 EN 9102 ECU input signal pressure SHEET 03 Connector X 9005 Fuel temperature sensor 87709793 3 87709793 CONNECTOR X 9005 Fuel temperature sensor PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 EN 9117 Engine Control Unit ECU input signal...

Page 638: ...ATIC FRAME 1 EN 9115 Engine Control Unit ECU input signal temperature 2 EN 9114 ECU reference ground SHEET 03 Connector X 9007 Fuel metering unit 87709793 5 87709793 CONNECTOR X 9007 Fuel metering unit PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 EN 9137 Switched 12 V supply voltage Engine Control Unit ECU 2 EN 9136 PWM Low side driver ECU SHEET 03 47866583_ 02 12 2015 55 ...

Page 639: ...r 87709793 6 87747172 CONNECTOR X 9008 Camshaft phase sensor PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 EN 9110 Reference ground Engine Control Unit ECU 2 EN 9111 Input signal ECU 3 EN 9109 5 V sensor supply ECU SHEET 03 47866583_ 02 12 2015 55 4 55 100 74 ...

Page 640: ...sor supply Engine Control Unit ECU 2 EN 9135 H bridge Pulse Width Modulated PWM supply ECU 3 EN 9100 Reference ground ECU SHEET 03 4 5 EN 9099 Position signal ECU 6 EN 9134 H bridge Pulse Width Modulated PWM supply ECU SHEET 03 Connector X 9016 Oil pressure switch 87687239 2 87687239 CONNECTOR X 9016 Oil pressure switch PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 EN 9105 ...

Page 641: ...ector X 9026 Rail pressure sensor 84130322 1 84146683 CONNECTOR X 9026 Rail pressure sensor PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 EN 9106 Reference ground Engine Control Unit ECU 2 EN 9107 Input signal ECU 3 EN 9108 5 V sensor supply ECU SHEET 03 47866583_ 02 12 2015 55 4 55 100 76 ...

Page 642: ...CAL SCHEMATIC FRAME 1 EN 9125 High Side Driver HSD Engine Control Unit ECU 2 EN 9126 Low Side Driver LSD Engine Control Unit ECU SHEET 03 Connector X 9031 Cylinder 3 injector Bank 2 Injector 1 87709793 2 87709793 CONNECTOR X 9031 Cylinder 3 injector PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 EN 9127 High Side Driver HSD Engine Control Unit ECU 2 EN 9128 Low Side Driver L...

Page 643: ...RENCE ELECTRICAL SCHEMATIC FRAME 1 EN 9129 High Side Driver HSD Engine Control Unit ECU 2 EN 9130 Low Side Driver LSD Engine Control Unit ECU SHEET 03 Connector X 9034 Cylinder 1 glow plug 1 928 404 879 4 1 928 404 879 CONNECTOR X 9034 Cylinder 1 glow plug PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 GP 1 Glow plug supply SHEET 01 47866583_ 02 12 2015 55 4 55 100 78 ...

Page 644: ...CUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 GP 2 Glow plug supply SHEET 01 Connector X 9036 Cylinder 3 glow plug 1 928 404 879 6 1 928 404 879 CONNECTOR X 9036 Cylinder 3 glow plug PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 GP 3 Glow plug supply SHEET 01 Connector X 9039 Crankshaft speed sensor 87747172 7 87747172 47866583_ 02 12 2015 55 4 55 100 79 ...

Page 645: ...ensor PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 EN 9138 Input signal positive Engine Control Unit ECU 2 EN 9139 Input signal negative Engine Control Unit ECU 3 EN 9140 Reference ground Engine Control Unit ECU SHEET 03 47866583_ 02 12 2015 55 4 55 100 80 ...

Page 646: ...relay switched fused supply shared source K05 K04 VE 9211 Ground Battery minus negative terminal K05 VE 9076 Main relay switched fused supply shared source K03 K06 VE 9212 Ground Battery minus negative terminal K07 VE 9200 Low Side Driver LSD DEF AdBlue tank heating valve K08 VE 9048 Input signal Key switch start position SHEET 02 K09 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 VE 9073 Inp...

Page 647: ...ence ground GCU SHEET 02 K42 K43 K44 K45 K46 K47 K48 K49 K50 K51 K52 VE 9072 LSD GCU K53 VE 9173 HSD Starter control relay K54 VE 9053 Input signal Key switch ON ACC position SHEET 02 K55 K56 K57 K58 K59 K60 K61 K62 K63 VE 9156 Input signal Lambda sensor voltage nernst K64 VE 9154 Input signal Lambda sensor current pump SHEET 02 K65 K66 K67 K68 ISO K Interface Diagnostic and monitoring connector K...

Page 648: ...E 9147 Input signal Exhaust gas temperature DOC sensor SHEET 02 K81 K82 K83 VE 9153 Reference ground Exhaust gas temperature POC sensor K84 VE 9152 Input signal Exhaust gas temperature POC sensor K85 VE 9155 Reference ground Lambda sensor K86 VE 9157 Input signal Lambda sensor current adjust SHEET 02 K87 K88 VE 9077 Input signal Water in fuel switch SHEET 02 K89 K90 K91 K92 K93 K94 47866583_ 02 12...

Page 649: ... positive 5 VE 9074 Reference ground ECU SHEET 01 6 7 VE 9059 High Side Driver HSD Glow plug 2 8 VE 9072 Control signal ECU SHEET 01 Connector X 9116 Engine shut off relay NOTE Relays are in product relay panels See product service manual for pinout image of this connector CONNECTOR X 9116 Engine shut off relay PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 85 VE 9089 Switched...

Page 650: ... VE 9174 Low side switched control Engine Control Unit ECU 86 VE 9173 High side switched control ECU 87 VE High side control Crank relay SHEET 01 87A Connector X 9123 Lambda sensor 84301132 1 84301132 CONNECTOR X 9123 Lambda sensor PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 VE 9154 Current pump input Engine Control Unit ECU 2 VE 9155 Reference ground ECU 3 VE 9200 Low si...

Page 651: ...ntrol Unit ECU 2 VE 9085 Switched source voltage Main ECU power relay 3 VE 9078 Frame ground SHEET 02 Connector X 9126 Exhaust gas temperature Diesel Oxidation Catalyst DOC sensor 87709793 3 87709793 CONNECTOR X 9126 Exhaust gas temperature DOC sensor PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 1 VE 9147 Input signal Engine Control Unit ECU 2 VE 9188 Reference ground ECU SH...

Page 652: ...3 Reference ground ECU SHEET 02 Connector X 9129 Main ECU power relay NOTE Relays are in product relay panels See product service manual for pinout image of this connector CONNECTOR X 9129 Main ECU power relay PIN NUMBER WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME 30 VE 9087 VE 9086 12 V source Battery positive 85 VE 9086 12 V source battery positive 86 VE 9084 Low side switched contr...

Page 653: ...4 FUSE ECU 02 Fuse Component Type Fuse Wiring frames SHEET 02 F 005 LAMBDA PROBES Fuse Component Type Fuse Wiring frames SHEET 02 F 006 CLUSTER HOT Fuse Component Type Fuse Wiring frames SHEET 02 F 007 WORK LAMP Fuse Component Type Fuse Wiring frames SHEET 02 F 008 HIGH LOW BEAM Fuse Component Type Fuse Wiring frames SHEET 02 F 009 STARTER SWITCH Fuse Component Type Fuse Wiring frames SHEET 02 F 0...

Page 654: ...ET 02 F 015 FLASHER Fuse Component Type Fuse Wiring frames SHEET 06 F 016 CLUSTER FT Fuse Component Type Fuse Wiring frames SHEET 06 F 017 HAZARD HOT Fuse Component Type Fuse Wiring frames SHEET 06 F 018 HORN LIGHT SW Fuse Component Type Fuse Wiring frames SHEET 06 F 019 SAFETY LOGIC Fuse Component Type Fuse Wiring frames SHEET 06 F 020 BECON LAMP Fuse Component Type Fuse Wiring frames SHEET 06 47...

Page 655: ...ource description G 001 BATTERY Voltage source Component Type Voltage source Wiring frames SHEET 03 Connectors X 001A Male X 001B Male G 002 ALTERNATOR Voltage source Component Type Voltage source Wiring frames SHEET 03 Connectors X 209 Male 47866583_ 02 12 2015 55 4 55 100 90 ...

Page 656: ...MP Relay Component Type Relay Wiring frames SHEET 04 K 006 HIGH BEAM Relay Component Type Relay Wiring frames SHEET 04 K 007 LOW BEAM Relay Component Type Relay Wiring frames SHEET 04 K 008 PTO SAFETY START Relay Component Type Relay Wiring frames SHEET 04 K 009 STOP LIGHT Relay Component Type Relay Wiring frames SHEET 04 K 010 ENGINE SHUT OFF Relay Component Type Relay Wiring frames SHEET 04 K 01...

Page 657: ...rical systems Harnesses and connectors K 013 FRONT LOADER Relay Component Type Relay Wiring frames SHEET 02 K 014 HEATER Relay Component Type Relay Wiring frames SHEET 02 47866583_ 02 12 2015 55 4 55 100 92 ...

Page 658: ...ystems Harnesses and connectors Electrical components Motor description M 001 STARTER MOTOR Motor Component Type Motor Wiring frames SHEET 03 Connectors X 004A Male X 206 Female 47866583_ 02 12 2015 55 4 55 100 93 ...

Page 659: ...nectors X 003 Female S 007 HOME ENTER Switch Component Type Switch Wiring frames SHEET 07 Connectors X 018 Female X 019 Female S 008 UP DOWN Switch Component Type Switch Wiring frames SHEET 07 Connectors X 020 Female X 021 Female S 009 JOYSTICK LOADER Switch Component Type Switch Wiring frames SHEET 06 Connectors X 520 Female 47866583_ 02 12 2015 55 4 55 100 94 ...

Page 660: ...e then cut away outer protective cover on both sides of the damaged area GNIL14TR04711AA 1 2 Peel back the cable from both ends of the damaged area and carefully cut away the inner cable cover at the damaged area and strip about 13 00 mm 0 51 in of insulation from the wires Do not cut away any wire strands 3 Using a suitable solvent clean about 50 00 mm 1 97 in from each cover end Clean the grey c...

Page 661: ...lap of at least 50 00 mm 1 97 in of tape at each end is necessary figure 4 7 Check to ensure the repair is satisfactory and secure the repaired cable so that repeat damage is avoided NOTE This is a temporary repair only Ensure the dam aged cable is replaced as soon as possible to prevent ingress of water or chemicals GNIL14TR04714AA 4 47866583_ 02 12 2015 55 4 55 100 96 ...

Page 662: ...l shutoff solenoid and replace as necessary Wiring harnesses Troubleshooting Safety start circuit Operator not present Problem Possible Cause Correction Starter motor will not energize Insufficient battery charge Test battery Charge add water or replace as necessary Blown fusible link Inspect and replace fusible link as neces sary Defective key switch Test key switch and replace as necessary Defec...

Page 663: ...tion Operator not present PTO OFF Problem Possible Cause Correction Engine does not continue to run while operator is seated Defective neutral safety switch Test neutral safety switch and replace as necessary Blown 3 A diode Check diode replace if necessary Defective Fuel shutoff relay Test relay and replace as necessary Malfunctioning fuel shutoff solenoid Test fuel shutoff solenoid and replace a...

Page 664: ...Defective operator safety module Test module and replace as necessary Open wiring in safe operation circuit Check for loose connectors grounds and wiring damage Engine does not continue to run when operator is not in seat transmission is in neutral PTO is on and park brake is engaged Defective range neutral switch PTO switch or 3 A diode Test components and replace as neces sary 47866583_ 02 12 20...

Page 665: ...sheet 02 Engine Control Unit ECU power and after treat ment system engine schematics 28 Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 30 Electrical components Fuse description 88 Electrical components Motor description 93 Electrical components Relay description 91 Electrical components Switch description 94 Electrical components Voltage source d...

Page 666: ...nt diagram 71 68 Wire connectors Component diagram 90 69 Wiring harnesses Electrical schematic sheet 02 SH02 POWER DISTRIBUTION GEP FUSE BOX 4 Wiring harnesses Repair 95 Wiring harnesses Troubleshooting Safe Operation Operator Present 98 Wiring harnesses Troubleshooting Safe operation Operator not present PTO OFF 98 Wiring harnesses Troubleshooting Safe operation Operator not present PTO ON 98 Wir...

Page 667: ...47866583_ 02 12 2015 55 4 55 100 102 ...

Page 668: ...Electrical systems 55 Engine starting system 201 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 5 55 201 1 ...

Page 669: ... systems 55 Engine starting system 201 FUNCTIONAL DATA Engine starting system Dynamic description 3 SERVICE Engine starter Remove 5 Install 6 DIAGNOSTIC Engine starter Troubleshooting 7 47866583_ 02 12 2015 55 5 55 201 2 ...

Page 670: ...es a high speed motor that utilizes a gear reduction unit an overrunning pinion clutch 12 and permanent magnets 4 in a field coil 5 for magnetic field induction The reduction unit consists of a small drive gear 2 on the motor armature 6 which drives an idler gear 14 in the reduction unit The idler gear is splined to the gear on the pinion clutch housing 12 When the starter solenoid 10 is energized...

Page 671: ...on gear from the rest of the starter components once the en gine has been started and the key switch is in the START position The clutch consists of an outer gear shell 1 a cam with tapered notches 2 rollers 3 roller springs 4 a splined pinion collar tube that acts as a clutch hub 5 and the pinion shaft 6 As the starter motor engages and rotates the rollers are locked against the pinion collar wit...

Page 672: ... 2 Disconnect the electrical connection from the starter motor GNIL14TR00713AA 1 3 Remove the set screw 1 on the front axle support It interferes while the starter motor mounting bolts are loosened GNIL14TR00736AA 2 4 Loosen the starter motor mounting bolts Remove the starter motor GNIL14TR00735AA 3 47866583_ 02 12 2015 55 5 55 201 5 ...

Page 673: ...Electrical systems Engine starting system Engine starter Install For installation follow the removal process in reverse order 47866583_ 02 12 2015 55 5 55 201 6 ...

Page 674: ...nion teeth worn Replace Starter motor Pinion push out position de fective Adjust Engine Ring gear worn Replace Solenoid defective Replace Pinion meshes with ring gear but starting motor fails to turn Wiring Line connecting solenoid to battery broken or defective ground Repair or replace Wiring Lead wire connecting solenoid to motor tightened improperly Repair or replace Starting motor Ball bearing...

Page 675: ...lectrical systems 55 Engine starting system 201 Engine starter Install 6 Engine starter Remove 5 Engine starter Troubleshooting 7 Engine starting system Dynamic description 3 47866583_ 02 12 2015 55 5 55 201 8 ...

Page 676: ...Electrical systems 55 Alternator 301 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 6 55 301 1 ...

Page 677: ...Contents Electrical systems 55 Alternator 301 DIAGNOSTIC Alternator Troubleshooting 3 47866583_ 02 12 2015 55 6 55 301 2 ...

Page 678: ...ective regulator Replace Regulator Loose connection of alternator and regulator Repair Battery Defective Battery Replace Overcharge Battery Internal short Replace Regulator Defective regulator Replace Unstable Charging Circuit Wiring Loose connection or open wire Repair or replace Alternator Loose drive belt Repair Alternator Short in rotor coil Replace Alternator Short in stator coil Replace Alte...

Page 679: ...Index Electrical systems 55 Alternator 301 Alternator Troubleshooting 3 47866583_ 02 12 2015 55 6 55 301 4 ...

Page 680: ...Electrical systems 55 Battery 302 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 7 55 302 1 ...

Page 681: ...Contents Electrical systems 55 Battery 302 SERVICE Battery Remove 3 Check 4 Install 5 47866583_ 02 12 2015 55 7 55 302 2 ...

Page 682: ... When reconnecting batteries always connect the negative cable last Failure to comply could result in death or serious injury W0264A 1 Unlatch and raise the hood to gain access to the bat tery 2 Remove the negative cable 1 from the negative terminal on the battery 3 Remove the positive cable 2 from the positive terminal on the battery 4 Remove the nut washer and J bolt 3 which secures the battery ...

Page 683: ...parks open flames and other ignition sources Never charge a frozen battery Failure to comply could result in death or serious injury W0005A 1 The battery is located in front of the radiator The battery electrolyte level should be between the minimum and maximum lines provided on battery con tainer If necessary top off with distilled or de mineralized wa ter until the level is correct Do not overfi...

Page 684: ...ge occurs from the battery 4 Install the battery squarely into position before securing with strap and J bolt 1 5 Connect the negative terminal 2 then the positive terminal 3 NOTE Coat the battery terminal clamps with petroleum jelly or equivalent Do not use conventional lubricants as electrolyte corrosion may occur 6 Check battery terminal connections for correct polarity and tightness Do not ove...

Page 685: ...Index Electrical systems 55 Battery 302 Battery Check 4 Battery Install 5 Battery Remove 3 47866583_ 02 12 2015 55 7 55 302 6 ...

Page 686: ...Electrical systems 55 External lighting 404 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 8 55 404 1 ...

Page 687: ...l and or hazard lights Replace 4 DIAGNOSTIC External lighting Troubleshooting Lighting circuit 5 Turn signal and or hazard lights Troubleshooting Hazard lighting circuit 6 Troubleshooting Right turn signal circuit 6 Troubleshooting Left turn signal circuit 6 47866583_ 02 12 2015 55 8 55 404 2 ...

Page 688: ...External lighting Headlight Replace 1 Remove the electrical connector 1 GNIL14TR00534AA 1 2 Remove the rubber boot 2 3 Change a burned out bulb for another halogen bulb of the same power 47866583_ 02 12 2015 55 8 55 404 3 ...

Page 689: ...two screws 1 and take out the lens assembly 2 The bulbs can be removed by pressing in and turning approximately 20 degree counterclockwise Reassemble in reverse order 20108813 1 Tail light 3 and flasher turn signal light 4 NOTICE When replacing the lenses take care not to over tighten the retaining screws Bulb Size Tail Light 1157 Flasher Turn Signal 1156 20108814 2 47866583_ 02 12 2015 55 8 55 40...

Page 690: ...Taillight bulb fault Check and replace bulb as necessary Blown fusible link Inspect fusible link and replace as neces sary Blown fuse head park 20 A fuse Replace fuse as necessary Defective light switch Test light switch and replace as necessary Improper connection at taillight lamp termi nals or lamp socket Check connections and lamp socket Re pair or replace as necessary Improper ground connecti...

Page 691: ...sh Blown fuse turn horn 15 A hazard or direc tional signal fuse Inspect fuse and replace as necessary Blown fuse hazard 15 A fuse Inspect fuse and replace as necessary Directional signal bulb burnt out Inspect bulb and replace as necessary Defective directional signal switch Test switch and replace as necessary Defective hazard turn flasher module Test module and replace as necessary Faulty wiring...

Page 692: ...mage corrosion and short circuits Repair or replace as needed Instrument panel turn indicator does not illuminate Indicator bulb burnt out Inspect bulb and replace as necessary Faulty wiring or ground connection Inspect the tractor s wiring harness and ground terminals for damage corrosion and short circuits Repair or replace as needed 47866583_ 02 12 2015 55 8 55 404 7 ...

Page 693: ...Replace 3 Turn signal and or hazard lights Replace 4 Turn signal and or hazard lights Troubleshooting Hazard lighting circuit 6 Turn signal and or hazard lights Troubleshooting Left turn signal circuit 6 Turn signal and or hazard lights Troubleshooting Right turn signal circuit 6 47866583_ 02 12 2015 55 8 55 404 8 ...

Page 694: ...Electrical systems 55 External lighting switches and relays 405 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 9 55 405 1 ...

Page 695: ...Contents Electrical systems 55 External lighting switches and relays 405 FUNCTIONAL DATA Brake light switch Overview 3 47866583_ 02 12 2015 55 9 55 405 2 ...

Page 696: ...ys Brake light switch Overview The brake pedal switch 1 is located below the right foot board near the foot brake It is actuated while applying brake and is indicated by the light provided on the fender GNIL14TR04724AB 1 47866583_ 02 12 2015 55 9 55 405 3 ...

Page 697: ...Index Electrical systems 55 External lighting switches and relays 405 Brake light switch Overview 3 47866583_ 02 12 2015 55 9 55 405 4 ...

Page 698: ...Electrical systems 55 Warning indicators alarms and instruments 408 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 10 55 408 1 ...

Page 699: ...rms and instruments 408 FUNCTIONAL DATA Warning indicators alarms and instruments Overview 3 Instrument cluster Overview 5 SERVICE Instrument cluster Remove 9 Install 12 DIAGNOSTIC Instrument cluster Troubleshooting 16 47866583_ 02 12 2015 55 10 55 408 2 ...

Page 700: ... direction of travel between forward and reverse Hazard switch The hazard switch 3 activates the hazard flasher lights Use the hazard flasher lights when traveling on public roads day or night Head light switch The head light switch 4 consists of four positions refer to Head Light Switch Positions Central display navigation buttons The menus of the central liquid crystal display on the instrument ...

Page 701: ... The hazard warning lights switch 3 1 activates the hazard flashing warning lights 1 located on each side of the ROPS 2 The hazard flashing warning lights can be activated with the key switch in any position For your protection use the flasher warning lights and the SMV Slow Moving Vehicle emblem 3 when travelling on public roads day or night 76099309N 3 Trailer electrical socket A standard 7 pin ...

Page 702: ...cator light flashes together with the tractor trailer direction indicators if the first trailer is connected 2 Full beam headlights blue This indicator light will illuminate when the tractor lights are switched to high beam 3 Side lights green This indicator light is illuminated when the tractor lights are turned on 4 Stop warning light red If the red Stop warning light comes on switch off the tra...

Page 703: ...s indicator light flashes at the same time as the tractor s right direction indicator With the tractor running if the turn signal is not switched off within 20 seconds an intermittent alarm comes on This audible warning comes on if the direction indicator is not turned off within five minutes with the tractor stationary 11 Warning light of the Diesel Particulate Filter DPF green For more details s...

Page 704: ...long time at speeds between 2500 3000 RPM yellow area on the speedometer to avoid damage to the engine and definitely never exceed 3000 RPM red area on the speedometer For appropriate use always operate under the speed corresponding to 2300 RPM DCUTLBRNE003S3A 2 Engine coolant temperature gauge The temperature display 1 indicates the temperature of the engine coolant blue area normal temperature r...

Page 705: ... Slip Data displayed by pressing and releasing the button ENTER A Tractor direction Speed of the vehicle in Km h or MPH Tractor working hour meter Kilometers travelled Area worked Area worked per hour Battery voltage Data displayed by pressing the arrow buttons up or down B When necessary warning and error messages Programming menu see specific chapter DCAPLT5NE005S3F 5 GNIL14TR00512AA 6 47866583_...

Page 706: ...OTE Always disconnect the negative cable 1 first GNIL14TR00784AA 1 3 Remove the steering wheel cover 1 GNIL14TR00512AA 2 4 Loosen the steering wheel securing nut GNIL14TR00846AA 3 5 Loosen the steering wheel securing nut and remove the steering wheel using tool number 82834312 and 9971375 GNIL14TR00704AA 4 47866583_ 02 12 2015 55 10 55 408 9 ...

Page 707: ...wiring connection 1 near the steering column GNIL14TR00711AA 5 7 Loosen the bolt 1 and remove the shuttle lever GNIL14TR00705AA 6 8 Remove the hand throttle knob GNIL14TR00706AA 7 9 Unscrew all the screws of instrument panel GNIL14TR00707AA 8 47866583_ 02 12 2015 55 10 55 408 10 ...

Page 708: ...cators alarms and instruments 10 Pull out the instrument panel from rear hood 11 Disconnect all the electric connections of the switches and hourmeter from the instrument cluster GNIL14TR00714AA 9 47866583_ 02 12 2015 55 10 55 408 11 ...

Page 709: ... Connect wiring coupler to horn switch GNIL14TR00772AA 1 2 Connect wiring coupler to head light switch GNIL14TR00773AA 2 3 Connect wiring coupler to indicator switch GNIL14TR00774AA 3 4 Connect wiring coupler to programming arrow switch GNIL14TR00775AA 4 47866583_ 02 12 2015 55 10 55 408 12 ...

Page 710: ...pler to home programming switch GNIL14TR00776AA 5 6 Connect wiring coupler to Hi Lo beam switch GNIL14TR00777AA 6 7 Connect wiring coupler to hazard warning switch GNIL14TR00778AA 7 8 Tighten all the screws 1 of instrument panel GNIL14TR00707AA 8 47866583_ 02 12 2015 55 10 55 408 13 ...

Page 711: ...d throttle knob GNIL14TR00706AA 9 10 Fit the shuttle lever and tighten the bolt 1 GNIL14TR00705AA 10 11 Connect the wiring coupler 1 near the steering col umn GNIL14TR00711AA 11 12 Install the steering wheel and cover 1 GNIL14TR00512AA 12 47866583_ 02 12 2015 55 10 55 408 14 ...

Page 712: ...Electrical systems Warning indicators alarms and instruments 13 Connect the battery terminals 1 and 2 GNIL14TR00784AA 13 47866583_ 02 12 2015 55 10 55 408 15 ...

Page 713: ...t Check ground connections for proper con tact Faulty sender Check sender for proper operation Warning lights not illuminating Bulb is burned out Replace bulb Sender wire damaged Check wiring harness for damage Faulty sender Check sender for proper operation Gauges always show maximum reading Sender wire shorted to ground Check sender wire for damage Erratic tachometer reading Fan belt slipping Ti...

Page 714: ...rs alarms and instruments 408 Instrument cluster Install 12 Instrument cluster Overview 5 Instrument cluster Remove 9 Instrument cluster Troubleshooting 16 Warning indicators alarms and instruments Overview 3 47866583_ 02 12 2015 55 10 55 408 17 ...

Page 715: ...47866583_ 02 12 2015 55 10 55 408 18 ...

Page 716: ...Electrical systems 55 Cab controls 512 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 11 55 512 1 ...

Page 717: ...Contents Electrical systems 55 Cab controls 512 SERVICE Joystick and Electric Hydraulic EH control Remove 3 Install 5 47866583_ 02 12 2015 55 11 55 512 2 ...

Page 718: ... on the connectors of joystick cable 3 Slide the connector on the joystick cable GNIL14TR00764AA 1 2 Remove the roll pin 1 and remove the joystick cable GNIL14TR00821AA 2 3 Similarly remove the other joystick cable GNIL14TR00788AA 3 4 Loosen the screws 1 and remove the cover 2 of the joystick GNIL14TR00786AA 4 47866583_ 02 12 2015 55 11 55 512 3 ...

Page 719: ...Electrical systems Cab controls 5 1 Disconnect the electrical coupling 2 Loosen the bolts 1 and remove the joystick from the mounting bracket GNIL14TR00787AA 5 47866583_ 02 12 2015 55 11 55 512 4 ...

Page 720: ... the screws 2 GNIL14TR00786AA 2 3 Insert the roll pin 1 and connect the joystick cable passing through the footboard on the mid mount valve NOTE Connect the green colored cable on the upper port of the mid mount valve Connect the yellow colored cable on the lower port of the mid mount valve GNIL14TR00821AA 3 4 Tighten the set screw 1 on the connector of the joy stick cable Tighten the locknut 2 GN...

Page 721: ...Index Electrical systems 55 Cab controls 512 Joystick and Electric Hydraulic EH control Install 5 Joystick and Electric Hydraulic EH control Remove 3 47866583_ 02 12 2015 55 11 55 512 6 ...

Page 722: ...Electrical systems 55 FAULT CODES DTC Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 55 12 55 DTC 1 ...

Page 723: ...cted ECU 32 DTC 137 02 Fuel pressure relief valve reached maximum allowed opening count ECU 34 DTC 137 03 Fuel pressure relief valve is open ECU 35 DTC 137 04 Fuel pressure relief valve is forced to open perform pressure increase ECU 36 DTC 137 12 Averaged rail pressure is outside the expected tolerance range ECU 37 DTC 141 02 Crankshaft speed sensor values are not plausible ECU 38 DTC 141 04 Cran...

Page 724: ...sor heater power stage short circuit to battery ECU 90 DTC 18F 04 Lambda sensor heater power stage short circuit to ground ECU 92 DTC 18F 04 Lambda sensor heater power stage short circuit to ground ECU 94 DTC 199 02 Turbocharger boost pressure is higher than expected ECU 96 DTC 199 02 Turbocharger boost pressure is higher than expected ECU 97 DTC 1B1 03 CAN A Bus off failure ECU 98 DTC 1B1 04 CAN ...

Page 725: ... open perform pressure shock ECU 155 DTC 237 04 Fuel pressure relief valve is forced to open perform pressure shock ECU 156 DTC 237 12 Quantity balance check if a successful PRV opening is ensured ECU 157 DTC 237 12 Quantity balance check if a successful PRV opening is ensured ECU 158 DTC 238 03 Oil pressure switch active with engine off ECU 159 DTC 238 04 Low oil pressure ECU 161 DTC 256 03 Engin...

Page 726: ...9 DTC 3E3 00 ECU internal failure Fuel injection energizing time is not plausible ECU 210 DTC 3E3 01 ECU internal failure Fuel injection energizing phase is not plausible ECU 211 DTC 3E3 02 Fuel injection correction has exceeded a minimum limit ECU 212 DTC 3E3 03 ECU internal failure Injection quantity correction ECU 213 DTC 3E3 04 ECU internal failure Rail pressure plausibility ECU 214 DTC 3E3 12...

Page 727: ...to air control exceeds maximum torque limit ECU 259 DTC 5E3 12 ECU internal failure Torque request exceeds maximum torque limit ECU 260 DTC 601 02 Lambda sensor nernst cell open circuit ECU 261 DTC 602 02 Lambda sensor pump current open circuit ECU 263 DTC 605 03 Lambda sensor O2 value above maximum threshold ECU 265 DTC 606 02 Lambda sensor virtual ground open circuit ECU 267 DTC 607 03 Lambda se...

Page 728: ...ed ECU 296 DTC 78B 04 Throttle valve actuator position sensor voltage is lower than expected ECU 298 DTC 78D 03 Throttle valve actuator control circuit over load ECU 300 DTC 78D 04 Throttle valve actuator control circuit supply voltage too low ECU 302 DTC 7BA 02 Timeout Error of CAN Receive Frame CM1BC ECU 303 47866583_ 02 12 2015 55 12 55 DTC 7 ...

Page 729: ...ontinue with Step 7 2 Use the EST to check for related faults that may have caused this fault to occur A If any other faults that may have caused this fault to occur are active resolve those faults first and then return to this fault B If no other faults are active continue with Step 3 3 Check the water in fuel switch S 9102 for the initial self test voltage pulse Carefully back probe the water in...

Page 730: ...in 3 Chassis ground There should be key switch voltage X 9125 pin 1 Chassis ground There should be no key switch voltage A If there is key switch voltage present in the first check and not present in the second check continue with Step 6 B If key switch voltage is not present in the first check or present in the second check use the appropriate vehicle service manual and schematics to diagnose and...

Page 731: ...vice Tool EST to check the fault status A If the fault is still present and active continue with Step 2 B If the fault is no longer present or is in an inactive state Continue with Step 7 2 Check fuel for water contamination A If there is water contamination continue with Step 3 B If there is no water contamination Continue with Step 4 3 Verify proper water in fuel switch S 9102 operation Purge fu...

Page 732: ...hould be no key switch voltage A If there is key switch voltage present in the first check and not present in the second check continue with Step 6 B If key switch voltage is not present in the first check or present in the second check use the appropriate vehicle service manual and schematics to diagnose and repair the wiring 6 Replace the water in fuel switch S 9102 then check to see if this fau...

Page 733: ... may be intermittent and not currently active Continue with Step 6 2 Check the coolant temperature sensor B 9003 wiring for a short circuit Disconnect the engine harness EN from the coolant temperature sensor B 9003 at connector X 9006 With the key in the OFF position use a multimeter to perform the following voltage check on the engine harness side From To Value X 9006 pin 1 Chassis ground There ...

Page 734: ...r the shorted conductor 5 Replace the engine coolant temperature sensor B 9003 Use the EST to verify the status of the this fault A If the fault is no longer active return the machine to service B If the fault is still active check the ECU A 9000 for the appropriate software and re flash if necessary 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corrod...

Page 735: ...ture sensor B 9003 engine harness EN wiring for a short to ground condition Disconnect the engine harness EN from the coolant temperature sensor B 9003 at connector X 9006 With the key in the OFF position use a multimeter to perform the following continuity check on the engine harness EN side To From Value X 9006 pin 1 X 9006 pin 2 There should be no continuity X 9006 pin 1 Chassis ground There sh...

Page 736: ...installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If ...

Page 737: ...tinue with Step 6 2 Check the intake manifold temperature sensor B 9001 wiring for a short to battery condition Disconnect the engine harness EN from the intake manifold temperature sensor B 9001 at connector X 9003 With the key in the OFF position use a multimeter to perform the following voltage check on the engine harness EN side From To Value X 9003 pin 2 Chassis ground There should be no volt...

Page 738: ...ontinuity leave connector X 9003 disconnected and continue to Step 5 5 Replace the intake manifold temperature sensor B 9001 Use the Electronic Service Tool EST to check the status of this fault A If the fault is no longer active return the machine to service B If the fault is still active check the ECU A 9000 for the appropriate software and re flash if necessary 6 Visually inspect the relevant h...

Page 739: ...nect the engine harness EN from the intake manifold temperature sensor B 9001 at connector X 9003 With the key in the OFF position use a multimeter to perform the following continuity check on the engine harness EN side From To Value X 9003 pin 2 X 9003 pin 1 There should be no continuity X 9003 pin 2 Chassis ground There should be no continuity A If there is continuity there is a short to ground ...

Page 740: ...are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been reso...

Page 741: ...134 03 Intake manifold pressure sensor voltage is higher than expected DTC 134 04 Intake manifold pressure sensor voltage is lower than expected A If any of the listed faults are active diagnose them first and then return to this fault B If none of the listed faults are active continue to Step 3 3 Replace the intake manifold pressure sensor B 9001 Use the EST to verify the status of this fault A I...

Page 742: ...tage is higher than expected DTC 134 04 Intake manifold pressure sensor voltage is lower than expected A If any of the listed faults are active diagnose them first and then return to this fault B If none of the listed faults are active continue to Step 3 3 Replace the intake manifold pressure sensor B 9001 Use the EST to verify the status of this fault A If the fault is no longer active return the...

Page 743: ...tep 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the intake manifold pressure sensor B 9001 wiring for a short to a voltage source Disconnect the engine harness EN from the intake manifold pressure sensor B 9001 at connector X 9003 With the key in the OFF position use a multimeter to perform the fo...

Page 744: ...engine harness EN Locate and repair the shorted conductor B If there is no continuity leave connector X 9003 disconnected and continue to Step 5 5 Replace the intake manifold pressure sensor B 9001 Use the Electronic Service Tool EST to check the status of this fault A If the fault is no longer active return the machine to service B If the fault is still active check the ECU A 9000 for the appropr...

Page 745: ...resent or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the intake manifold pressure sensor B 9001 wiring in the engine harness EN for a short to ground condi tion Disconnect the engine harness EN from the intake manifold pressure sensor B 9001 at connector X 9003 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 Wit...

Page 746: ... the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Ele...

Page 747: ...th Step 6 2 Check the fuel temperature sensor B 9002 for an internal failure Disconnect the engine harness EN from the fuel temperature sensor B 9002 at connector X 9005 Use a multimeter to measure the resistance of the fuel temperature sensor B 9002 on the sensor pins From To Value X 9005 pin 1 X 9005 pin 2 At approximately 20 0 C 68 0 F there should be between 2351 2648 Ω NOTE The fuel temperatu...

Page 748: ...rness EN wiring for a short circuit condition With the key in the OFF position use the a multimeter to perform the following continuity check on the engine harness EN side From To Value X 9001 pin A38 All pins in connector X 9001 There should be no continuity A If there is continuity there is a short circuit in the fuel temperature sensor B 9002 wiring in the engine harness EN Locate and repair th...

Page 749: ...nnector X 9005 Use a multimeter to measure the resistance of the fuel temperature sensor B 9002 on the sensor pins From To Value X 9005 pin 1 X 9005 pin 2 At approximately 20 0 C 68 0 F there should be between 2351 2648 Ω NOTE The fuel temperature sensor B 9002 is a Negative Temperature Coefficient NTC thermistor The thermis tor s conductivity increases with increasing temperature and resistance d...

Page 750: ...ate software and re flash if necessary 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates...

Page 751: ...sent and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the rail pressure sensor B 9004 wiring for a short circuit condition Disconnect the engine harness EN from the rail pressure sensor B 9004 at connector X 9026 With the key in the OFF position use a multimeter to perform...

Page 752: ...9026 disconnected and continue to Step 5 5 Replace the rail pressure sensor B 9004 Use the Electronic Service Tool EST to check the status of this fault A If the fault is no longer active return the machine to service B If the fault is still active check the ECU A 9000 for the appropriate software and re flash if necessary 6 Visually inspect the relevant harnesses and connectors for damage bent or...

Page 753: ... intermittent and not currently active Continue with Step 5 2 Check the rail pressure sensor B 9004 engine harness EN wiring for a short circuit condition Disconnect the engine harness EN from the rail pressure sensor B 9004 at connector X 9026 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the OFF position use a multimeter to perform the following continu...

Page 754: ...eveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display ind...

Page 755: ...l pressure sensor Configure Reset ECU data Rail pressure sensor 55 010 if necessary Context The Engine Control Unit ECU A 9000 monitors the fuel Pressure Relief Valve PRV If the ECU A 9000 determines that the PRV has exceeded its maximum open count 50 times this fault will occur If the PRV has opened more than 50 times the PRV must be replaced Other active faults may have caused this fault to occu...

Page 756: ...chine to service See Common rail pressure sensor Configure Reset ECU data Rail pressure sensor 55 010 if necessary Context The Engine Control Unit ECU A 9000 monitors the Pressure Relief Valve PRV If the ECU A 9000 commands the PRV to open by a pressure shock this fault will occur Other active faults may have caused this fault to occur For more information regarding fuel system troubleshooting see...

Page 757: ...mmon rail pressure sensor Configure Reset ECU data Rail pressure sensor 55 010 if necessary Context The Engine Control Unit ECU A 9000 if necessary will set the engine into limp home mode This process is achieved in two steps by the ECU A 9000 a pressure increase and a pressure shock The ECU A 9000 will execute step one by a fuel pressure increase This is achieved by fully opening the fuel meterin...

Page 758: ...ata Rail pressure sensor 55 010 if necessary Context The Engine Control Unit ECU A 9000 monitors fuel rail pressure using the rail pressure sensor B 9004 After a fuel pressure evaluation if the ECU A 9000 suspects that the Pressure Relief Valve PRV should be open but has not opened this fault occur If this fault is active the ECU A 9000 has performed step one for achieving limp home mode a fuel pr...

Page 759: ...2 Check the physical integrity of the crankshaft position sensor B 9007 The sensor should be fully seated and mounted tightly Remove the crankshaft position sensor B 9007 and inspect the crankshaft tool wheel The tone wheel should not be damaged or loose A If the sensor or tone wheel is damaged or is not mounted secured properly repair as necessary B If the sensor or tone wheel is not damaged and ...

Page 760: ...EN Locate and repair the broken conductor 6 Replace the crankshaft position sensor B 9007 Use the Electronic Service Tool EST to verify the status of this fault A If the fault has been resolved return the machine to service B If the fault has not been resolved check the ECU A 9000 for the appropriate software and re flash if necessary 7 Visually inspect the relevant harnesses and connectors for da...

Page 761: ... 2 Check the physical integrity of the crankshaft position sensor B 9007 The sensor should be fully seated and mounted tightly Remove the crankshaft position sensor B 9007 and inspect the crankshaft tool wheel The tone wheel should not be damaged or loose A If the sensor or tone wheel is damaged or is not mounted secured properly repair as necessary B If the sensor or tone wheel is not damaged and...

Page 762: ...should be no continuity A If there is no continuity leave connector X 9039 disconnected and continue to Step 6 B If there is no continuity there is an open circuit in the crankshaft position sensor B 9007 circuit wiring in the engine harness EN Locate and repair the broken conductor 6 Replace the crankshaft position sensor B 9007 Use the Electronic Service Tool EST to verify the status of this fau...

Page 763: ...ty of the camshaft speed sensor B 9017 The sensor should be fully seated and mounted tightly A If the sensor is not mounted secured properly repair as necessary B If the sensor is not damaged and is mounted secured properly continue to Step 3 3 Check the camshaft position sensor B 9017 wiring in the engine harness EN for an open circuit Disconnect the engine harness EN from the camshaft position s...

Page 764: ...ent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and r...

Page 765: ...ysical integrity of the camshaft speed sensor B 9017 The sensor should be fully seated and mounted tightly A If the sensor is not mounted secured properly repair as necessary B If the sensor is not damaged and is mounted secured properly continue to Step 3 3 Check the camshaft position sensor B 9017 wiring in the engine harness EN for an open circuit Disconnect the engine harness EN from the camsh...

Page 766: ...ault has not been resolved check the ECU A 9000 for the appropriate software and re flash if necessary 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you m...

Page 767: ...mines that the offset between the crankshaft signal and the expected camshaft first edge is less or greater than 10 00 for longer than four consecutive cycles this fault will occur Possible failure modes 1 Faulty camshaft position sensor B 9017 improperly mounted or not fully seated 2 Faulty crankshaft position sensor B 9007 improperly mounted or not fully seated 3 Faulty camshaft tone wheel loose...

Page 768: ... Unit ECU A 9000 monitors fuel rail pressure If the measured rail pressure is lower than the de sired pressure by 100 bar 1450 psi depending on engine speed this fault will occur For more information regarding fuel system troubleshooting see Fuel injection system Troubleshooting 10 218 Cause The ECU A 9000 has determined that the measured rail pressure is 100 bar 1450 psi lower than desired fuel p...

Page 769: ... on engine speed Possible failure modes 1 Faulty fuel metering unit Y 9000 wiring broken or poor connections 2 Faulty fuel metering unit Y 9000 stuck open 3 Faulty fuel back flow clogged or damaged 4 Faulty Pressure Relief Valve PRV stuck or blocked 5 Faulty rail pressure sensor B 9004 drifted 6 Faulty high pressure pump 7 Faulty ECU A 9000 software Solution 1 Verify fault is present and active Us...

Page 770: ... inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair t...

Page 771: ...he rail pressure sensor B 9004 If the ECU A 9000 determines that the measured rail pressure is less than a dependent engine speed value this fault will occur Other active faults may have caused this fault to occur For more information regarding fuel system troubleshooting see Fuel injection system Troubleshooting 10 218 Cause The ECU A 9000 has determined that the measured rail pressure is less th...

Page 772: ...ssible failure modes 1 Faulty fuel metering unit Y 9000 wiring broken or poor connections 2 Faulty fuel metering unit Y 9000 stuck open or internal failure 3 Faulty fuel back flow lines blocked or damaged 4 Faulty Pressure Relief Valve PRV stuck closed or mechanically unable to open 5 Faulty high pressure pump zero delivery throttle valve clogged 6 Faulty rail pressure sensor B 9004 drifted signal...

Page 773: ...spect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the ...

Page 774: ...ned that the high pressure fuel pump quantity is higher than the expected fuel quantity threshold Possible failure modes 1 Faulty low pressure fuel system clogged filter or leakage blockage 2 Faulty charge gear pump low efficiency or line clogged damaged 3 Faulty electric fuel pump if equipped 4 Faulty fuel metering unit unable to fully open 5 Faulty high pressure pump low efficiency 6 Faulty fuel...

Page 775: ...ntrol Unit ECU Y 9000 monitors fuel rail pressure If the ECU A 9000 determines that the requested fuel pressure can not be reached a leakage in the fuel system is assumed and this fault will occur For more infor mation regarding fuel system troubleshooting see Fuel injection system Troubleshooting 10 218 Cause The ECU A 9000 has determined that a fuel system leakage is present Possible failure mod...

Page 776: ...onnector X 9007 Use a multimeter to measure the resistance on the fuel metering unit Y 9000 pins From To Value X 9007 pin 1 X 9007 pin 2 There should be between 2 6 3 2 Ω at approximately 20 0 C 68 0 F A If there is between 2 6 3 2 Ω leave connector X 9007 disconnected and continue to Step 3 B If there is not between 2 6 3 2 Ω the fuel metering unit Y 9000 has failed Replace the fuel metering unit...

Page 777: ... the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Ele...

Page 778: ... Unit ECU monitors the Particulate Matter PM catalytic converter efficiency If the ECU A 9000 detects an failure of efficiency inducement will be triggered and this fault will occur Other active faults may have caused this fault to occur This fault indicates the least severe level of inducement 47866583_ 02 12 2015 55 12 55 DTC 57 ...

Page 779: ...njector number 1 Y 9001 internal resistance Disconnect the engine harness EN from the fuel injector number 1 Y 9001 at connector X 9030 Use a multimeter to measure the resistance of fuel injector number 1 Y 9001 on the injector pins From To Value X 9030 pin 1 X 9030 pin 2 There should be between 03 05 Ω A If there is between 03 05 Ω leave connector X 9030 disconnected and continue to Step 3 B If t...

Page 780: ...e harness EN Use the appropriate service manual if necessary to locate and repair the shorted conductor B If there is no continuity continue with Step 6 6 Check the ECU A 9000 voltage supply wiring Disconnect the vehicle harness VE from the ECU A 9000 at connector X 9102 Place a jumper wire between X 9102 pin K28 and chassis ground This will energize the main relay K 9102 Use a multimeter to perfo...

Page 781: ...matics 55 100 DP C 20 E 01 Wiring harnesses Electrical schematic sheet 02 Engine Control Unit ECU power and after treatment system engine schematics 55 100 DP C 20 E 02 Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC 60 ...

Page 782: ... fuel injector number 1 Y 9001 internal resistance Disconnect the engine harness EN from the fuel injector number 1 Y 9001 at connector X 9030 Use a multimeter to measure the resistance of fuel injector number 1 Y 9001 on the injector pins From To Value X 9030 pin 1 X 9030 pin 2 There should be between 03 05 Ω A If there is between 03 05 Ω leave connector X 9030 disconnected and continue to Step 3...

Page 783: ...oltage supply Use the appropriate service manual if necessary to locate and repair the failed conductor B If there is approximately 12 0 V check the ECU A 9000 for the appropriate software and re flash if necessary 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the ha...

Page 784: ... number 2 Y 9002 internal resistance Disconnect the engine harness EN from the fuel injector number 2 Y 9002 at connector X 9032 Use a multimeter to measure the resistance of fuel injector number 2 Y 9002 on the injector pins From To Value X 9032 pin 1 X 9032 pin 2 There should be between 03 05 Ω A If there is between 03 05 Ω leave connector X 9032 disconnected and continue to Step 3 B If the resi...

Page 785: ...e harness EN Use the appropriate service manual if necessary to locate and repair the shorted conductor B If there is no continuity continue with Step 6 6 Check the ECU A 9000 voltage supply wiring Disconnect the vehicle harness VE from the ECU A 9000 at connector X 9102 Place a jumper wire between X 9102 pin K28 and chassis ground This will energize the main relay K 9102 Use a multimeter to perfo...

Page 786: ...matics 55 100 DP C 20 E 01 Wiring harnesses Electrical schematic sheet 02 Engine Control Unit ECU power and after treatment system engine schematics 55 100 DP C 20 E 02 Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC 65 ...

Page 787: ...6 2 Check the fuel injector number 2 Y 9002 internal resistance Disconnect the engine harness EN from the fuel injector number 2 Y 9002 at connector X 9032 Use a multimeter to measure the resistance of fuel injector number 2 Y 9002 on the injector pins From To Value X 9032 pin 1 X 9032 pin 2 There should be between 03 05 Ω A If there is between 03 05 Ω leave connector X 9032 disconnected and conti...

Page 788: ...3 X 9102 pin K04 There should be approximately 12 0 V X 9102 pin K05 X 9102 pin K06 There should be approximately 12 0 V A If there is not approximately 12 0 V there is a faulty ECU A 9000 voltage supply Use the appropriate service manual if necessary to locate and repair the failed conductor B If there is approximately 12 0 V check the ECU A 9000 for the appropriate software and re flash if neces...

Page 789: ... number 3 Y 9003 internal resistance Disconnect the engine harness EN from the fuel injector number 3 Y 9003 at connector X 9031 Use a multimeter to measure the resistance of fuel injector number 3 Y 9003 on the injector pins From To Value X 9031 pin 1 X 9031 pin 2 There should be between 03 05 Ω A If there is between 03 05 Ω leave connector X 9031 disconnected and continue to Step 3 B If the resi...

Page 790: ...ropriate service manual if necessary to locate and repair the shorted conductor B If there is no continuity continue with Step 6 6 Check the ECU A 9000 voltage supply wiring Disconnect the vehicle harness VE from the ECU A 9000 at connector X 9102 Place a jumper wire between X 9102 pin K28 and chassis ground This will energize the main relay K 9102 Use a multimeter to perform the following voltage...

Page 791: ...matics 55 100 DP C 20 E 01 Wiring harnesses Electrical schematic sheet 02 Engine Control Unit ECU power and after treatment system engine schematics 55 100 DP C 20 E 02 Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC 70 ...

Page 792: ...r 3 Y 9003 internal resistance Disconnect the injector harness INJ from the fuel injector number 3 Y 9003 at connector X 9031 Use a multimeter to measure the resistance of fuel injector number 3 Y 9003 on the injector pins From To Value X 9031 pin 1 X 9031 pin 2 There should be between 03 05 Ω A If there is between 03 05 Ω leave connector X 9031 disconnected and continue to Step 3 B If the resista...

Page 793: ...ion use a multimeter to perform the following continuity check on the vehicle harness VE side From To Value X 9122 pin K02 chassis ground There should be continuity X 9122 pin K04 chassis ground There should be continuity X 9122 pin K06 chassis ground There should be continuity A If there is no continuity there is a faulty ECU A 9000 ground supply Use the appropriate service manual if necessary to...

Page 794: ...ctive state the fault may be intermittent and not currently active Continue with Step 4 2 Check fuel injector number 1 for an internal failure Disconnect the engine harness EN from fuel injector number 1 Y 9001 at connector X 9030 Use a multimeter to perform the following resistance check on the fuel injector pins From To Value X 9030 pin 1 X 9030 pin 2 There should be approximately 0 3 0 5 Ω A If...

Page 795: ... the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Ele...

Page 796: ...ctive state the fault may be intermittent and not currently active Continue with Step 4 2 Check fuel injector number 2 for an internal failure Disconnect the engine harness EN from fuel injector number 2 Y 9002 at connector X 9032 Use a multimeter to perform the following resistance check on the fuel injector pins From To Value X 9032 pin 1 X 9032 pin 2 There should be approximately 0 3 0 5 Ω A If...

Page 797: ... the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Ele...

Page 798: ...ctive state the fault may be intermittent and not currently active Continue with Step 4 2 Check fuel injector number 3 for an internal failure Disconnect the engine harness EN from fuel injector number 3 Y 9003 at connector X 9031 Use a multimeter to perform the following resistance check on the fuel injector pins From To Value X 9031 pin 1 X 9031 pin 2 There should be approximately 0 3 0 5 Ω A If...

Page 799: ... the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Ele...

Page 800: ... fuel injector 1 Y 9001 harness for a short circuit condition Disconnect the engine harness EN from fuel injector number 1 Y 9001 at connector X 9030 With the key in the OFF position use a multimeter to perform the following continuity check on the engine harness EN side From To Value X 9030 pin 1 X 9030 pin 2 There should be no continuity A If there is continuity there is a short circuit in the f...

Page 801: ...to this fault B If none of the related faults are active continue to Step 3 3 Check the fuel injector 2 and 3 harnesses for a short circuit condition Disconnect the engine harness EN from fuel injector number 2 Y 9002 at connector X 9032 Disconnect the engine harness EN from fuel injector number 3 Y 9003 at connector X 9031 With the key in the OFF position use a multimeter to perform the following...

Page 802: ...te and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC 81 ...

Page 803: ...attern detection to identify specific errors and can trigger the appropriate reaction If the ECU A 9000 detects a specific combination of errors in the injection power stages this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIS...

Page 804: ... connector X 9102 Place a jumper wire between X 9102 pin K28 and chassis ground This will energize the main relay K 9102 Use a multimeter to perform the following voltage checks on the engine harness EN side From To Value X 9102 pin K01 X 9102 pin K02 There should be approximately 12 0 V X 9102 pin K03 X 9102 pin K04 There should be approximately 12 0 V X 9102 pin K05 X 9102 pin K06 There should b...

Page 805: ...ns is greater than the current capability of the fuel injection system for the current engine speed this fault will occur Cause The ECU A 9000 has determined that the requested number of fuel injections is greater than the capability of the fuel injection system based on engine speed Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been reso...

Page 806: ...U A 9000 determines that the requested number of fuel injections can not be reached this fault will occur Cause The ECU A 9000 has determined that the requested number of fuel injections is greater than the current capability of the fuel injection system Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to ser...

Page 807: ...ction system Troubleshooting 10 218 Cause The ECU A 9000 has determined that the number of requested fuel injections is greater than the current capability of the fuel injection system to fulfill that request Possible failure modes 1 Faulty fuel back flow excessive 2 Faulty high pressure pump worn or ageing 3 Faulty fuel metering unit unable to open 4 Faulty fuel temperature too high 5 Faulty fuel...

Page 808: ...MA codes 10 218 Cause The ECU A 9000 has determined that the fuel injector number 1 Y 9001 fuel trim correction can not be performed Solution 1 Use the Electronic Service Tool EST ensure that the correct IMA code is programmed to fuel injector number 1 Y 9001 A If the correct code is not programmed Use the EST to program the correct code B If the correct code is programmed continue to Step 2 NOTE ...

Page 809: ...a sensor B 9123 failed internally 4 Faulty ECU A 9000 software Solution 1 Verify that the fault present and active Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the Lambda se...

Page 810: ...ECU A 9000 for the appropriate software and re flash if necessary 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find dama...

Page 811: ...iring short to a voltage source 2 Faulty Lambda sensor B 9123 internal failure 3 Faulty ECU A 9000 software Solution 1 Verify that the fault present and active Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently acti...

Page 812: ...ropriate software and re flash if necessary 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indi...

Page 813: ...ty Lambda sensor B 9123 failed internally 3 Faulty ECU A 9000 software Solution 1 Verify that the fault present and active Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check the L...

Page 814: ...evant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov...

Page 815: ...lty ECU A 9000 software Solution 1 Verify that the fault present and active Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the Lambda sensor B 9123 heater control circuit wiri...

Page 816: ...oncerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault co...

Page 817: ...hat boost pressure is higher than expected this fault will occur For more information regarding the troubleshooting of an over boost condition see Turbocharger Troubleshooting 10 250 Cause The ECU A 9000 has determined that boost pressure is higher than expected Possible failure modes 1 Faulty wastegate sticking or broken linkage 2 Faulty intake manifold pressure sensor B 9001 signal drifted 3 Fau...

Page 818: ...n expected this fault will occur For more information regarding the troubleshooting of an over boost condition see Turbocharger Troubleshooting 10 250 Cause The ECU A 9000 has determined that boost pressure is higher than expected Possible failure modes 1 Faulty wastegate pressure modulator valve Y 9008 if applicable 2 Faulty wastegate sticking or broken linkage 3 Faulty intake manifold pressure s...

Page 819: ...nt or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolve those vehicle CAN faults first then check to see that this fault is also resolved B If other vehicle CAN faults do not exist continue with Step 3 3 Check the...

Page 820: ...nded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in ...

Page 821: ...esent or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolve those vehicle CAN faults first then check to see that this fault is also resolved B If other vehicle CAN faults do not exist continue with Step 3 3 Check ...

Page 822: ...d refer to the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts i...

Page 823: ...tware Solution 1 Verify fault is present and in active state Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step2 B If the fault is no longer present or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle ...

Page 824: ...f necessary B If the measured resistances are not correct or one or both of the conductors is grounded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the conn...

Page 825: ...se the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step2 B If the fault is no longer present or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolv...

Page 826: ...f necessary B If the measured resistances are not correct or one or both of the conductors is grounded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the conn...

Page 827: ...ol EST to check the status of this fault A If the fault is present and active continue with Step2 B If the fault is no longer present or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolve those vehicle CAN faults f...

Page 828: ...f necessary B If the measured resistances are not correct or one or both of the conductors is grounded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the conn...

Page 829: ...Service Tool EST to check the status of this fault A If the fault is present and active continue with Step2 B If the fault is no longer present or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolve those vehicle CA...

Page 830: ...f necessary B If the measured resistances are not correct or one or both of the conductors is grounded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the conn...

Page 831: ...ing the sensor supplies communication If the ECU A 9000 detects a communication error during this diagnostic check this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 110 ...

Page 832: ...f the EEPROM and sets a status flag depending on if an error is found or not found These flags are processed every 20 milliseconds by the Diagnostic System Management DSM and if the value is out of range this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not b...

Page 833: ... a memory media Flash or EEPROM If the ECU A 9000 determines that this process can not be performed or successfully completed this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 112 ...

Page 834: ... the EEPROM and sets a status flag depending on if an error is found or not found These flags are processed every 20 milliseconds by the Diagnostic System Management DSM and if the value is out of range this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not be...

Page 835: ... of the EEPROM and sets a status flag depending on if an error is found or not found These flags are processed every 20 milliseconds by the Diagnostic System Management DSM and if the value is out of range this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not...

Page 836: ...the Engine Control Unit ECU A 9000 has detected an error that has led to a software reset Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 115 ...

Page 837: ...ween the ECU A 9000 processor and the power stage controller over the SPI bus If there is an error in the communication this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 116 ...

Page 838: ...he ECU A 9000 processor and the power stage controller over the SPI bus If there is an error in the communication this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 117 ...

Page 839: ...C plausibility by performing a fixed input voltage test If the voltage during the test is out of range this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 118 ...

Page 840: ...onverter ADC for plausibility by providing a test voltage to be converted If the converted voltage is out of range this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 119 ...

Page 841: ...ADC plausibility by running a No load Test Pulse operation NTP If the ECU A 9000 detects an error during this operation this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 120 ...

Page 842: ...sion from fuel quantity to torque for consistency If there is an error during this conversion check this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 121 ...

Page 843: ...il resistance on the starter control relay K 9104 pins From To Value X 9120 pin 85 X 9120 pin 86 There should be approximately 70 130 Ω A If there is approximately 70 130 Ω leave the starter control relay K 9104 disconnected and continue to Step 3 B If there is not approximately 70 130 Ω the relay has failed Replace the starter control relay K 9104 3 Check the starter control relay K 9104 high sid...

Page 844: ...mage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate...

Page 845: ...coil resistance on the starter control relay K 9104 pins From To Value X 9120 pin 85 X 9120 pin 86 There should be approximately 70 130 Ω A If there is approximately 70 130 Ω leave the starter control relay K 9104 disconnected and continue to Step 3 B If there is not approximately 70 130 Ω the relay has failed Replace the starter control relay K 9104 3 Check the starter control relay K 9104 high s...

Page 846: ...lled Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you d...

Page 847: ...ded fuel injection quantity of actual injection and actual fuel pressure If the ECU A 9000 determines that ener gizing time is greater than engine speed this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02...

Page 848: ... software levels If the ECU A 9000 deter mines that there is plausibility error in the engine speed monitoring this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 127 ...

Page 849: ...ssure and temperature sensor B 9001 wiring or internal failure 8 Faulty rail pressure sensor B 9004 wiring or internal failure 9 Faulty exhaust manifold pressure sensor B 9005 wiring to internal failure 10 Faulty camshaft speed sensor B 9017 wiring or internal failure 11 Faulty ECU A 9000 software Solution 1 Verify fault is present and active Use the Electronic Service Tool EST to check the status...

Page 850: ...re should be approximately 12 V A If there is approximately 12 V remove the jumper wire and re connect the ECU A 9000 at connector X 9102 then continue to Step 5 B If there is not approximately 12 V there is a failure in the ECU A 9000 supply wiring Use the appropriate service manual if necessary to locate and repair the failed conductor 5 Disconnect each of the following connectors one at a time ...

Page 851: ...hould be no voltage With the key in the OFF position use a multimeter to perform the following continuity checks on the engine harness EN side From To Value X 9003 pin 3 Chassis ground There should be no continuity X 9003 pin 3 X 9003 pin 1 There should be no continuity With the key in the OFF position use a multimeter to perform the following continuity checks on the vehicle harness VE side From ...

Page 852: ...A If the specified values are measured re connect all of the connectors and continue to Step 10 B If the specified values are not measured there is a failure in the camshaft speed sensor B 9017 voltage supply wiring Use the appropriate service manual if necessary to locate and repair the failed conductor 10 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault ...

Page 853: ... longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the battery voltage Charge the battery then perform a load test on the battery A If the battery passes the load test continue to Step 3 B If the battery fails the load test the battery has failed Replace the battery 3 Check the ECU A 9000 supply voltage Disconnect the ECU A 9...

Page 854: ...been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while y...

Page 855: ...o longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the battery voltage Charge the battery then perform a load test on the battery A If the battery passes the load test continue to Step 3 B If the battery fails the load test the battery has failed Replace the battery 3 Check the ECU A 9000 supply voltage Disconnect the ECU A ...

Page 856: ... ASIST concern 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal displ...

Page 857: ... range check of the atmospheric pressure sensor value If the ECU A 9000 determines that the value is too high this fault will occur The atmospheric pressure sensor is internal to the ECU A 9000 Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST c...

Page 858: ... range check of the atmospheric pressure sensor value If the ECU A 9000 determines that the value is too low this fault will occur The atmospheric pressure sensor is internal to the ECU A 9000 Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST co...

Page 859: ...esent and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the PM catalytic converter inlet temperature sensor B 9127 for an internal failure Disconnect the vehicle harness from the PM catalytic converter inlet temperature sensor B 9127 at connector X 9127 Use a multimeter to ...

Page 860: ...se a multimeter to perform the following continuity check on the vehicle harness VE side From To Value X 9102 pin K83 All pins in connector X 9102 There should be no continuity X 9102 pin K84 All pins in connector X 9102 There should be no continuity X 9127 pin 2 X 9127 pin 1 There should be no continuity X 9127 pin 1 Chassis ground There should be no continuity A If there is continuity there is a...

Page 861: ...p 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the PM catalytic converter inlet temperature sensor B 9127 for an internal failure Disconnect the vehicle harness from the PM catalytic converter inlet temperature sensor B 9127 at connector X 9127 Use a multimeter to measure the resistance on the PM c...

Page 862: ...n the OFF position use a multimeter to perform the following continuity check on the vehicle harness VE side From To Value X 9102 pin K83 All pins in connector X 9102 There should be no continuity X 9102 pin K84 All pins in connector X 9102 There should be no continuity A If there is continuity there is a short circuit in the PM catalytic converter inlet temperature sensor B 9127 ve hicle harness ...

Page 863: ...e state the fault may be intermittent and not currently active Continue with Step 5 2 Check the PM catalytic converter inlet temperature sensor B 9127 for an internal failure Disconnect the vehicle harness from the PM catalytic converter inlet temperature sensor B 9127 at connector X 9127 Use a multimeter to measure the resistance on the PM catalytic converter inlet temperature sensor B 9127 pins ...

Page 864: ...ctor B If there is no continuity check the ECU A 9000 for the appropriate software and re flash if necessary 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while...

Page 865: ... to measure the resistance on the main relay K 9102 pins From To Value X 9129 pin 85 X 9129 pin 86 There should be approximately 70 130 Ω A If there is approximately 70 130 Ω leave the main relay K 9102 disconnected and continue to Step 3 B If there is not approximately 70 130 Ω the main relay K 9102 has failed Replace the main relay K 9102 3 Check the main relay K 9102 low side driver wiring for ...

Page 866: ...rce Re connect the main relay K 9102 With the key in the OFF position use a multimeter to perform the following voltage checks for a short to a voltage source on the vehicle harness VE side From To Value X 9102 pin K01 Chassis ground There should be no voltage X 9102 pin K03 Chassis ground There should be no voltage X 9102 pin K05 Chassis ground There should be no voltage A If there is voltage the...

Page 867: ...nce on the main relay K 9102 pins From To Value X 9129 pin 85 X 9129 pin 86 There should be approximately 70 130 Ω A If there is approximately 70 130 Ω leave the main relay K 9102 disconnected and continue to Step 3 B If there is not approximately 70 130 Ω the main relay K 9102 has failed Replace the main relay K 9102 3 Check the main relay K 9102 vehicle harness VE wiring for a short to a voltage...

Page 868: ... broken or damaged conductor B If there is continuity leave the main relay K 9102 and connector X 9102 disconnected then continue to Step 6 6 Check the main relay K 9102 wiring for a short circuit condition With the key in the OFF position use a multimeter to perform the following continuity checks for a short circuit on the vehicle harness VE side From To Value X 9129 pin 85 X 9129 pin 86 There s...

Page 869: ... 9000 for the appropriate software and re flash if necessary 9 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or...

Page 870: ...o perform the following voltage check on the battery posts From To Value Battery Battery 14 8 16 2 V A If the voltage is high out of range normal engine running operating range is approximately 14 8 16 2 V the alternator has failed Replace the alternator B If the voltage is within range normal engine running operating range is approximately 14 8 16 2 V check the ECU A 9000 for the appropriate soft...

Page 871: ...t the engine and raise the Revolutions Per Minute RPM to about 1500 RPM for 1 00 min Lower the RPM to idle speed and check the battery voltage with the engine running With the engine running use a multimeter to perform the following voltage check on the battery posts From To Value Battery Battery 14 8 16 2 V A If the voltage is low out of range normal engine running operating range is approximatel...

Page 872: ...ductor B If there is no continuity check the ECU A 9000 for the appropriate software and re flash if necessary 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine whi...

Page 873: ...essure sensor B 9004 is replaced it is necessary to perform the Replacement of the Rail Pressure sensor Reset ECU Data with the Electronic Service Tool EST before you return the machine to service See Common rail pressure sensor Configure Reset ECU data Rail pressure sensor 55 010 if necessary 47866583_ 02 12 2015 55 12 55 DTC 152 ...

Page 874: ...U A 9000 and stored in the EEPROM during after run This fault is for informational purposes only If this fault is active other fuel system faults may be active that caused this fault to occur Diagnose any faults that may have caused this one to occur first and then return to this fault DTC 237 Max Open time of PRV for wear out monitoring had exceeded maximum value For more information regarding fu...

Page 875: ...essure sensor B 9004 is replaced it is necessary to perform the Replacement of the Rail Pressure sensor Reset ECU Data with the Electronic Service Tool EST before you return the machine to service See Common rail pressure sensor Configure Reset ECU data Rail pressure sensor 55 010 if necessary 47866583_ 02 12 2015 55 12 55 DTC 154 ...

Page 876: ...ary will set the engine into limp home mode This process is achieved in two steps by the ECU A 9000 a pressure increase and a pressure shock The ECU A 9000 will execute step two by a fuel pressure shock This is achieved by setting injection quantity to zero If this fault is active the ECU A 9000 has performed step two for achieving limp home mode a fuel pressure shock Cause The ECU A 9000 has perf...

Page 877: ...ary will set the engine into limp home mode This process is achieved in two steps by the ECU A 9000 a pressure increase and a pressure shock The ECU A 9000 will execute step two by a fuel pressure shock This is achieved by setting injection quantity to zero If this fault is active the ECU A 9000 has performed step two for achieving limp home mode a fuel pressure shock Cause The ECU A 9000 has perf...

Page 878: ...oses only Other active faults may have caused this fault to occur The Engine Control Unit ECU A 9000 monitors the fuel Pressure Relief Valve PRV To determine mechanical wear out of the PRV the ECU A 9000 will perform a fuel pressure increase and pressure shock thus opening the PRV Both steps are recorded in the ECU A 9000 failure memory 47866583_ 02 12 2015 55 12 55 DTC 157 ...

Page 879: ...oses only Other active faults may have caused this fault to occur The Engine Control Unit ECU A 9000 monitors the fuel Pressure Relief Valve PRV To determine mechanical wear out of the PRV the ECU A 9000 will perform a fuel pressure increase and pressure shock thus opening the PRV Both steps are recorded in the ECU A 9000 failure memory 47866583_ 02 12 2015 55 12 55 DTC 158 ...

Page 880: ... from the oil pressure switch S 9016 at connector X 9016 Use a multimeter to check for continuity on the component side From To Value X 9016 pin 1 chassis ground There should be continuity A If there is continuity leave connector X 9016 disconnected and continue with Step 3 B If there is no continuity the oil pressure switch S 9016 has failed internally replace the oil pressure switch S 9016 3 Che...

Page 881: ...ng the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC ...

Page 882: ...nd not currently active Continue with Step 7 2 Check oil level Use the appropriate operator or service manual if necessary to determine if the lubrication system has the ap propriate amount of oil There should be at least the minimum acceptable level of oil A If there is at least the minimum acceptable level of oil continue with Step 3 B If there less than the minimum acceptable level of oil use t...

Page 883: ...rication system for blockage See Engine lubrication system Test 10 304 if necessary to determine if the lubrication system has the ap propriate amount of oil pressure Between 0 6 0 9 bar 8 7 13 0 psi is required to actuate the oil pressure switch S 9016 There should be at least the minimum acceptable level of oil pressure A If there is adequate oil pressure the oil pressure switch S 9016 has faile...

Page 884: ...elerator pedal signal fuel injection parameters or engine speed can cause an injection cut off If torque or injection quantity are not plausible and engine speed is greater than 1200 RPM this fault will occur Other active faults may have caused this fault to occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the mach...

Page 885: ...engine harness EN from the fuel metering unit Y 9000 at connector X 9007 Use a multimeter to measure the resistance on the fuel metering unit Y 9000 pins From To Value X 9007 pin 1 X 9007 pin 2 There should be between 2 6 3 2 Ω at approximately 20 0 C 68 0 F A If there is between 2 6 3 2 Ω leave connector X 9007 disconnected and continue to Step 3 B If there is not between 2 6 3 2 Ω the fuel meter...

Page 886: ... B If there is no continuity check the ECU A 9000 for the appropriate software and re flash if necessary 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you...

Page 887: ... been programmed to injector number 1 A If the correct IMA code is present continue to Step 2 B If the correct IMA code has not been uploaded program the correct IMA code NOTE The IMA code may be under the paint on the fuel injector NOTE For more information regarding programming IMA codes see Fuel injectors Configure IMA codes 10 218 2 Replace the fuel injector number 1 Y 9001 Use the Electronic ...

Page 888: ... been programmed to injector number 1 A If the correct IMA code is present continue to Step 2 B If the correct IMA code has not been uploaded program the correct IMA code NOTE The IMA code may be under the paint on the fuel injector NOTE For more information regarding programming IMA codes see Fuel injectors Configure IMA codes 10 218 2 Replace the fuel injector number 1 Y 9001 Use the Electronic ...

Page 889: ...text The Engine Control Unit ECU monitors the Particulate Matter PM catalytic converter efficiency If the ECU A 9000 detects an failure of efficiency an inducement warning will be triggered and this fault will occur Other active faults may have caused this fault to occur 47866583_ 02 12 2015 55 12 55 DTC 168 ...

Page 890: ...Unit ECU A 9000 monitors fuel rail pressure If the ECU A 9000 determines that fuel rail pressure is less than 130 0 bar 1885 0 psi or below a limit value from an ECU A 9000 calculated curve this fault will occur Other active faults may have caused this fault to occur For more information regarding fuel system troubleshooting see Fuel injection system Troubleshooting 10 218 Cause The ECU A 9000 has...

Page 891: ...tion can not be performed Solution 1 Use the Electronic Service Tool EST ensure that the correct IMA code is programmed to fuel injector number 2 Y 9002 A If the correct code is not programmed Use the EST to program the correct code B If the correct code is programmed continue to Step 2 NOTE The IMA code may be under the paint on the fuel injector NOTE For more information regarding programming IM...

Page 892: ...oubleshooting of an under boost condition see Turbocharger Troubleshooting 10 250 Cause The ECU A 9000 has determined that boost pressure is lower than expected Possible failure modes 1 Faulty intake plumbing boost leakage 2 Faulty air filter clogged 3 Faulty wastegate pressure modulator valve Y 9008 if applicable 4 Faulty boost pressure accumulator if applicable 5 Faulty wastegate sticking 6 Faul...

Page 893: ...e Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolve those vehicle CAN fau...

Page 894: ...f necessary B If the measured resistances are not correct or one or both of the conductors is grounded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the conn...

Page 895: ...ol EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolve those vehicle CAN faults ...

Page 896: ...f necessary B If the measured resistances are not correct or one or both of the conductors is grounded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the conn...

Page 897: ...is too high this fault will occur Cause The ECU A 9000 has determined that the internal ECU A 9000 temperature sensor value is too high Possible failure modes 1 Machine is operating in extreme environmental conditions 2 Faulty ECU A 9000 software Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B I...

Page 898: ...is too low this fault will occur Cause The ECU A 9000 has determined that the internal ECU A 9000 temperature sensor value is too low Possible failure modes 1 Machine is operating in extreme environmental conditions 2 Faulty ECU A 9000 software Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If ...

Page 899: ...that there is an internal SPI communication error this fault will occur Cause The ECU A 9000 has detected an error in the internal ECU A 9000 temperature sensor communication Possible failure modes 1 Faulty ECU A 9000 software Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not ...

Page 900: ...000 has detected an error on the R2S2 module low level chip driver for the power stage chips Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 179 ...

Page 901: ... if a software failure is detected If this fault is active a software failure has been reported and a software reset has occurred Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 180 ...

Page 902: ...ult check of the ROM memory If any checksum errors in ROM memory blocks are detected this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 181 ...

Page 903: ...sure the relay coil resistance on the starter control relay K 9104 pins From To Value X 9120 pin 85 X 9120 pin 86 There should be approximately 70 130 Ω A If there is approximately 70 130 Ω leave the starter control relay K 9104 disconnected and continue to Step 3 B If there is not approximately 70 130 Ω the relay has failed Replace the starter control relay K 9104 3 Check the starter control rela...

Page 904: ...ormal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic sheet 01 Power distribution and glow plugs engine sch...

Page 905: ... the relay coil resistance on the starter control relay K 9104 pins From To Value X 9120 pin 85 X 9120 pin 86 There should be approximately 70 130 Ω A If there is approximately 70 130 Ω leave the starter control relay K 9104 disconnected and continue to Step 3 B If there is not approximately 70 130 Ω the relay has failed Replace the starter control relay K 9104 3 Check the starter control relay K ...

Page 906: ...ecessary 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display rea...

Page 907: ... control relay K 9104 Use a multimeter to perform the following resistance check on the starter control relay K 9104 pins From To Value X 9120 pin 85 X 9120 pin 86 There should be approximately 70 130 Ω A If there is approximately 70 130 Ω leave the relay disconnected and continue to Step 3 B If there is not approximately 70 130 Ω the relay starter control relay K 9104 has failed Replace the start...

Page 908: ...ou find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic s...

Page 909: ...elay K 9104 Use a multimeter to measure the relay coil resistance on the starter control relay K 9104 pins From To Value X 9120 pin 85 X 9120 pin 86 There should be approximately 70 130 Ω A If there is approximately 70 130 Ω leave the starter control relay K 9104 disconnected and continue to Step 3 B If there is not approximately 70 130 Ω the relay has failed Replace the starter control relay K 91...

Page 910: ...ould be no continuity A If there is continuity there is a short circuit in the starter control relay K 9104 wiring in the vehicle harness VE Use the appropriate service manual if necessary to locate and repair the shorted conductor B If there is no continuity check the ECU A 9000 for the appropriate service manual and re flash if necessary 6 Visually inspect the relevant harnesses and connectors f...

Page 911: ...is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check each of the glow plugs for an open circuit condition Disconnect the vehicle harness VE from each of the glow plugs at connectors X 9034 X 9035 and X 9036 Use a multimeter to measure the resistance of the glow plug...

Page 912: ...spect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the ...

Page 913: ... intermittent and not currently active Continue with Step 4 2 Check each of the glow plug circuits for a short to a voltage source condition Disconnect the vehicle harness VE from the glow plug control module Z 9101 at connector X 9113 Disconnect the vehicle harness VE from each of the glow plugs With the key in the ON position use a multimeter to perform the following voltage check for a short to...

Page 914: ...te and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic sheet 01 Power distribution and glow plugs engine schematics 55 100 DP C 20 E 01 47866583_ 02 12 2015 55 12 55 DTC 193 ...

Page 915: ...ntinue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check each of the glow plugs for a short to ground condition Disconnect the vehicle harness VE from each of the glow plugs at connectors X 9034 X 9035 and X 9036 Use a multimeter to measure the resistance of each glow plug on the glow plug pin...

Page 916: ...ct the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the dam...

Page 917: ...tive continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check each of the glow plugs for a short to ground condition Disconnect the vehicle harness VE from each of the glow plugs at connectors X 9034 X 9035 and X 9036 Use a multimeter to measure the resistance of each glow plug on the glow p...

Page 918: ...ct the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the dam...

Page 919: ... to perform the following continuity and resistance check on the fuel metering unit Y 9000 pins From To Value X 9007 pin 2 Chassis ground There should be no continuity X 9007 pin 1 X 9007 pin 2 There should be between 2 6 3 2 Ω at approximately 20 C 68 F A If there is between 2 6 3 2 Ω and there is no continuity to ground leave connector X 9007 disconnected and continue to Step 3 B If the specifie...

Page 920: ... the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Ele...

Page 921: ... been programmed to injector number 2 A If the correct IMA code is present continue to Step 2 B If the correct IMA code has not been uploaded program the correct IMA code NOTE The IMA code may be under the paint on the fuel injector NOTE For more information regarding programming IMA codes see Fuel injectors Configure IMA codes 10 218 2 Replace the fuel injector number 2 Y 9002 Use the Electronic ...

Page 922: ... been programmed to injector number 2 A If the correct IMA code is present continue to Step 2 B If the correct IMA code has not been uploaded program the correct IMA code NOTE The IMA code may be under the paint on the fuel injector NOTE For more information regarding programming IMA codes see Fuel injectors Configure IMA codes 10 218 2 Replace the fuel injector number 2 Y 9002 Use the Electronic ...

Page 923: ...Engine Control Unit ECU monitors the Particulate Matter PM catalytic converter efficiency If the ECU A 9000 detects an failure of efficiency an inducement warning will be triggered and this fault will occur Other active faults may have caused this fault to occur 47866583_ 02 12 2015 55 12 55 DTC 202 ...

Page 924: ...tion can not be performed Solution 1 Use the Electronic Service Tool EST ensure that the correct IMA code is programmed to fuel injector number 3 Y 9003 A If the correct code is not programmed Use the EST to program the correct code B If the correct code is programmed continue to Step 2 NOTE The IMA code may be under the paint on the fuel injector NOTE For more information regarding programming IM...

Page 925: ...Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolve those vehicle C...

Page 926: ...f necessary B If the measured resistances are not correct or one or both of the conductors is grounded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the conn...

Page 927: ... relevant to fuel injection if certain ECU A 9000 errors are detected If an incorrect response to the power stage supply CY320 is detected during this test this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_...

Page 928: ...es all power stages relevant to fuel injection if certain ECU A 9000 errors are detected If there is a time out error during this test this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 ...

Page 929: ... all power stages relevant to fuel injection if certain ECU A 9000 errors are detected If there is a faulty communication detected during this test this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2...

Page 930: ...ery time the key is turned ON this test is performed to verify the correct functioning of the shut off procedure If an error is detected during the shut off test the fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 4786...

Page 931: ...gizing time for plausibility If the ECU A 9000 de termines that this value is implausible for either pilot main or post injection this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 2...

Page 932: ...zing start time for plausibility If the ECU A 9000 determines that this value is implausible for either pilot main or post injection this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DT...

Page 933: ...his fault will occur Cause The ZFC is used to compensate for aging injectors If the compensation limit is exceeded this fault will occur Possible failure modes 1 Faulty fuel injectors worn 2 Faulty ECU A 9000 software Solution 1 Use the appropriate service manual to perform a leakage test in the high pressure fuel system Also test the fuel injectors for internal and external leakage A If any fault...

Page 934: ...ZFC energizing time The ZFC is used to correct pilot injection quantity If the ECU A 9000 determines the energizing time of the ZFC is implausible this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 20...

Page 935: ...evels of monitoring because fuel pressure monitoring is a critical functionality If the ECU A 9000 sees an error in the level two monitoring but not in level one monitoring this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST ...

Page 936: ...e torque to allowed engine torque If the ECU A 9000 determines that requested engine torque is greater than maximum allowed torque this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC ...

Page 937: ...he fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the DOC inlet temperature sensor B 9127 for an internal failure Disconnect the vehicle harness VE from the DOC inlet temperature sensor B 9127 at connector X 9127 Use a multimeter to measure the resistance on the diesel oxidation catalyst inlet temperature senso...

Page 938: ...onnector X 9102 There should be no continuity A If there is continuity there is a short circuit in the DOC inlet temperature sensor B 9127 vehicle harness VE wiring Use the appropriate service manual if necessary to locate and repair the shorted conductor B If there is no continuity check the ECU A 9000 for the appropriate software and re flash if necessary 6 Visually inspect the relevant harnesse...

Page 939: ...tep 5 2 Check the DOC inlet temperature sensor B 9127 for an internal failure Disconnect the vehicle harness VE from the DOC inlet temperature sensor B 9127 at connector X 9127 Use a multimeter to measure the resistance on the DOC inlet temperature sensor B 9127 From To Value X 9127 pin 1 X 9127 pin 2 There should be between 170 2 849 7 Ω A If there is between 170 2 849 7 Ω leave connector X 9127 ...

Page 940: ...ect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the da...

Page 941: ...re should be approximately 12 0 V X 9102 pin K03 X 9102 pin K04 There should be approximately 12 0 V X 9102 pin K05 X 9102 pin K06 There should be approximately 12 0 V A If the voltage is not present for one or more of the checks use the appropriate service manual if necessary to repair the faulty conductor B If the voltage is present on all of the checks check the ECU A 9000 for the appropriate s...

Page 942: ...ere should be approximately 12 0 V X 9102 pin K03 X 9102 pin K04 There should be approximately 12 0 V X 9102 pin K05 X 9102 pin K06 There should be approximately 12 0 V A If the voltage is not present for one or more of the checks use the appropriate service manual if necessary to repair the faulty conductor B If the voltage is present on all of the checks check the ECU A 9000 for the appropriate ...

Page 943: ... Continue with Step 4 2 Check the rail pressure sensor B 9004 engine harness EN harness wiring for an open circuit or intermittent open circuit condition Disconnect the engine harness EN from the rail pressure sensor B 9004 at connector X 9026 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the OFF position use a multimeter to perform the following continui...

Page 944: ...te and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC 223 ...

Page 945: ...to this fault For more information regarding fuel system troubleshooting see Fuel injection system Troubleshooting 10 218 Cause The ECU A 9000 has determined that the requested fuel pressure is greater than the actual fuel pressure at idle Possible failure modes 1 Faulty low pressure fuel system clogged filter or leakage blockage 2 Faulty charge gear pump low efficiency or line clogged damaged 3 F...

Page 946: ...Value X 9007 pin 1 X 9007 pin 2 There should be between 2 6 3 2 Ω at approximately 20 0 C 68 0 F A If there is between 2 6 3 2 Ω leave connector X 9007 disconnected and continue to Step 3 B If there is not between 2 6 3 2 Ω the fuel metering unit Y 9000 has failed Replace the fuel metering unit Y 9000 3 Check the fuel metering unit Y 9000 engine harness EN wiring for an open circuit or intermitten...

Page 947: ...te and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC 226 ...

Page 948: ... been programmed to injector number 3 A If the correct IMA code is present continue to Step 2 B If the correct IMA code has not been uploaded program the correct IMA code NOTE The IMA code may be under the paint on the fuel injector NOTE For more information regarding programming IMA codes see Fuel injectors Configure IMA codes 10 218 2 Replace the fuel injector number 3 Y 9003 Use the Electronic ...

Page 949: ... been programmed to injector number 3 A If the correct IMA code is present continue to Step 2 B If the correct IMA code has not been uploaded program the correct IMA code NOTE The IMA code may be under the paint on the fuel injector NOTE For more information regarding programming IMA codes see Fuel injectors Configure IMA codes 10 218 2 Replace the fuel injector number 3 Y 9003 Use the Electronic ...

Page 950: ...tor X 9011 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the OFF position use a multimeter to perform the following continuity check for an open circuit at the engine harness EN side From To Value X 9011 pin 6 X 9001 pin A49 There should be continuity X 9011 pin 2 X 9001 pin A34 There should be continuity NOTE Wiggle the harness during the check to promot...

Page 951: ...te and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC 230 ...

Page 952: ...ort to battery condition Disconnect the engine harness EN from the throttle valve actuator Z 9001 at connector X 9011 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the ON position use a multimeter to perform the following voltage check for a short to battery on the engine harness EN side From To Value X 9011 pin 6 Chassis ground There should be no voltage...

Page 953: ...re is continuity there is a short circuit in the throttle valve actuator Z 9001 engine harness EN h bridge circuit Use the appropriate service manual if necessary to locate and repair the shorted conductor B If there is no continuity leave connector X 9011 disconnected and continue to Step 6 6 Replace the throttle valve actuator Z 9001 Use the Electronic Service Tool EST to check the status of thi...

Page 954: ...short to battery condition Disconnect the engine harness EN from the throttle valve actuator Z 9001 at connector X 9011 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the ON position use a multimeter to perform the following voltage check for a short to battery on the engine harness EN side From To Value X 9011 pin 6 Chassis ground There should be no volta...

Page 955: ...re is continuity there is a short circuit in the throttle valve actuator Z 9001 engine harness EN h bridge circuit Use the appropriate service manual if necessary to locate and repair the shorted conductor B If there is no continuity leave connector X 9011 disconnected and continue to Step 6 6 Replace the throttle valve actuator Z 9001 Use the Electronic Service Tool EST to check the status of thi...

Page 956: ...stages relevant to fuel injection if certain ECU A 9000 errors are detected If an over voltage condition is detected during this test this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 D...

Page 957: ...stages relevant to fuel injection if certain ECU A 9000 errors are detected If an under voltage condition is detected during this test this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 ...

Page 958: ...njection 2 by monitoring start angle and efficiency If the ECU A 9000 determines that there is an error during this check this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 237 ...

Page 959: ... performs a diagnostic fault check for post injection 2 If the ECU A 9000 determines that the post injection 2 quantity has exceeded the expected value this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 ...

Page 960: ...t ECU A 9000 performs a diagnostic fault check for post injection 3 If the ECU A 9000 determines that there is a post injection 3 plausibility error this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 ...

Page 961: ...be intermittent and not currently active Continue with Step 4 2 Check for damaged diagnostic circuit wiring Disconnect the vehicle harness VE from the ECU A 9000 at connector X 9102 With the key in the OFF position use a multimeter to check for continuity on the vehicle harness VE side From To Result X 9102 pin K22 chassis ground There should be no continuity X 9102 pin K22 all other pins in conne...

Page 962: ...while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wir...

Page 963: ...r than 111 96 C 233 53 F a warning is set and this fault will occur For more information regarding cooling system troubleshooting see Engine cooling system Troubleshooting 10 400 Cause A coolant temperature level warning has been set by the ECU A 9000 Possible failure modes 1 Coolant level low 2 Faulty cooling system leakage or blockage 3 Extremely high environmental temperature or heavy machine u...

Page 964: ...ors fuel rail pressure using the rail pressure sensor B 9004 If the ECU A 9000 determines that rail pressure has exceeded 1790 bar 25955 psi this fault will occur A Pressure Relief Valve PRV integral to the fuel rail is designed to open in the event of an over pressure in the fuel rail at approximately 1790 bar 25955 psi If the ECU A 9000 determines that rail pressure has exceeded this threshold a...

Page 965: ...quire any further action Other active faults may have caused this fault to occur The Engine Control Unit ECU A 9000 monitors for an engine overspeed condition An engine overspeed condition can occur from such conditions as downhill travel If an engine speed of at least 3100 RPM has been detected for at least 0 05 s this fault will occur 47866583_ 02 12 2015 55 12 55 DTC 244 ...

Page 966: ...sistance Disconnect the engine harness EN from the fuel metering unit Y 9000 at connector X 9007 Use a multimeter to measure the resistance on the fuel metering unit Y 9000 pins From To Value X 9007 pin 1 X 9007 pin 2 There should be between 2 6 3 2 Ω at approximately 20 0 C 68 0 F A If there is between 2 6 3 2 Ω leave connector X 9007 disconnected and continue to Step 3 B If there is not between ...

Page 967: ...f there is no continuity check the ECU A 9000 for the appropriate software and re flash if necessary 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you mon...

Page 968: ... command the TVA Z 9001 to open and close at a fast rate in order to attempt to unblock the actuator This fault is not caused by a wiring failure It is likely caused by an obstruction to the throttle valve flap or excessive carbon build up on the throttle valve seat For more information regarding TVA Z 9001 inspection see Throttle Valve Actuator TVA Inspect 55 014 Cause The ECU A 9000 has detected...

Page 969: ...l command the TVA Z 9001 to open and close at a fast rate in order to attempt to unblock the actuator This fault is not caused by a wiring failure It is likely caused by an obstruction to the throttle valve flap or excessive carbon build up on the throttle valve seat Cause The ECU A 9000 has detected a negative deviation between the required and measured position of the TVA Z 9001 The desired thro...

Page 970: ...output 1 h bridge wiring for a short to battery condition Disconnect the engine harness EN from the throttle valve actuator Z 9001 at connector X 9011 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the ON position use a multimeter to perform the following voltage check on the engine harness EN side From To Value X 9011 pin 6 Chassis ground There should be ...

Page 971: ... the fault is no longer active return the machine to service B If the fault is still active check the ECU A 9000 for the appropriate service manual and re flash if necessary 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent b...

Page 972: ...ctuator Z 9001 output 1 h bridge engine harness EN wiring for a short to ground con dition Disconnect the engine harness EN from the throttle valve actuator Z 9001 at connector X 9011 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the OFF position use a multimeter to perform the following continuity check on the engine harness EN side From To Value X 9011 ...

Page 973: ...rnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered du...

Page 974: ...e correction values from the EEPROM If the ECU A 9000 detects an error n the EEPROM block this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 253 ...

Page 975: ...nt to fuel in jection if certain ECU A 9000 errors are detected If an implausible response in the power stage feedback is detected during this test this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2...

Page 976: ...l injection if certain ECU A 9000 errors are detected If an alarm task can not be set or reset after having detected a time out error during this test this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 1...

Page 977: ...ages relevant to fuel injection if certain ECU A 9000 errors are detected If the ECU A 9000 determines that the test has failed this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 256...

Page 978: ...tages relevant to fuel injection if certain ECU A 9000 errors are detected If a time out in the power stage feedback is detected during this test this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 201...

Page 979: ...nput torque request that is calculated for determining fuel pressure If the ECU A 9000 determines that lead torque is less than the limited maximal torque this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ ...

Page 980: ...put torque request that is calculated for determining fuel pressure If the ECU A 9000 determines that lead torque is less than the limited maximal torque this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 0...

Page 981: ...he engine The ECU A 9000 compares inner torque to allowed inner torque If the ECU A 9000 determines that Inner torque is greater than allowed inner torque this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ ...

Page 982: ...of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the Lambda sensor B 9123 nernst signal circuit wiring for an open circuit condition Disconnect the vehicle harness VE from the Lambda sensor B 9123 at connector X 9123 Disconnect the v...

Page 983: ... A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical sche...

Page 984: ...atus of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the Lambda sensor B 9123 pump current control circuit wiring for an open circuit condition Disconnect the vehicle harness VE from the Lambda sensor B 9123 at connector X 9123 Disc...

Page 985: ... A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical sche...

Page 986: ...t is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the Lambda sensor B 9123 trim resistor circuit wiring for an open or short circuit condition Disconnect the vehicle harness VE from the Lambda sensor B 9123 at connector X 9123 Carefully disconnect the vehicle h...

Page 987: ...l display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical schematic sheet 02 Engine Control Unit ECU power and after treatmen...

Page 988: ...ol EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the Lambda sensor B 9123 virtual ground circuit wiring for an open circuit condition Disconnect the vehicle harness VE from the Lambda sensor B 9123 at conne...

Page 989: ... A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical sche...

Page 990: ... per stroke and the calibration is not inhibited due to a failure The measured oxygen signal during calibration should be between 0 200 0 200 V If the oxygen signal during this calibration is out of range higher than 0 200 V this fault will occur For more information regarding fuel system troubleshooting see Fuel injection system Troubleshooting 10 218 For information regarding the functional oper...

Page 991: ...per stroke and the calibration is not inhibited due to a failure The measured oxygen signal during calibration should be between 0 200 0 200 V If the oxygen signal during this calibration is out of range less than 0 200 V this fault will occur For more information regarding fuel system troubleshooting see Fuel injection system Troubleshooting 10 218 For information regarding the functional operati...

Page 992: ...t in a configuration of the initialization register which is hardware controlled The same configuration is calculated by software If both configurations are not identical the SPI is not plausible and this fault will occur For information regarding the functional operation of the Lambda sensor B 9123 see Lambda sensor Overview 55 989 For more information regarding the technical specifications of th...

Page 993: ...B 9123 supply circuit wiring 3 Faulty Lambda sensor B 9123 failed internally 4 Faulty ECU A 9000 software Solution 1 Verify that the fault present and active Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active...

Page 994: ... are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been res...

Page 995: ...n circuit 3 Faulty Lambda sensor B 9123 internal failure 4 Faulty ECU A 9000 software Solution 1 Verify that the fault present and active Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step ...

Page 996: ...sensor Configure Reset ECU data Lambda sensor 55 989 if necessary to perform the Replacement of the Lambda Sensor Reset ECU Data Use EST to check to see that this fault has been resolved A If the fault has been resolved return the machine to service B If this fault has not been resolved check the ECU A 9000 for the appropriate software and re flash if necessary 5 Visually inspect the relevant harn...

Page 997: ...e Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the Lambda sensor B 9123 circuit wiring for a short to ground condition Disconnect the vehicle harness VE from the Lambda sensor B 912...

Page 998: ...reaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal r...

Page 999: ...Faulty Lambda sensor B 9123 failed internally 4 Faulty ECU A 9000 software Solution 1 Verify that the fault present and active Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Visuall...

Page 1000: ...reaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal r...

Page 1001: ...iled internally 3 Faulty ECU A 9000 software Solution 1 Verify that the fault present and active Use the Electronic Service Tool EST to check the status of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 4 2 Check the Lambda sensor B 9123 nernst...

Page 1002: ... A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display condition and verify that the error has been resolved B If you do not find damage and the display indicates only normal readings then erase the fault code and continue operation Wiring harnesses Electrical sche...

Page 1003: ... to battery condition Disconnect the engine harness EN from the throttle valve actuator Z 9001 at connector X 9011 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the ON position use a multimeter to perform the following voltage check on the engine harness EN side From To Value X 9011 pin 2 Chassis ground There should be no voltage A If there is voltage the...

Page 1004: ... broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display conditio...

Page 1005: ... Step 5 2 Check the throttle valve actuator Z 9001 output 2 h bridge engine harness EN wiring for a short to ground con dition Disconnect the engine harness EN from the throttle valve actuator Z 9001 at connector X 9011 With the key in the OFF position use a multimeter to perform the following continuity check on the engine harness EN side From To Value X 9011 pin 2 Chassis ground There should be ...

Page 1006: ... for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or...

Page 1007: ...een CJ945 power stage chips and CY320 power stage voltage supplier If the ABE wire between the CJ 945 and CY320 becomes active due to an unknown reason this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 ...

Page 1008: ...er stage chips and CY320 power stage voltage supplier If the ABE wire between the CJ 945 and CY320 becomes active due to an over voltage detection this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 20...

Page 1009: ...er stage chips and CY320 power stage voltage supplier If the ABE wire between the CJ 945 and CY320 becomes active due to an under voltage detection this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2...

Page 1010: ... power stage chips and CY320 power stage voltage supplier If there is an unexpected communication during this process this fault will occur Solution 1 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST concern 47866583_ 02 12 2015 55 12 55 DTC 289 ...

Page 1011: ...us of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the glow plug for a short to ground condition Disconnect the engine harness EN from glow plug 1 R 9001 at connector X 9034 Use a multimeter to check on the component for a grounded ...

Page 1012: ... 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings th...

Page 1013: ...us of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the glow plug for a short to ground condition Disconnect the engine harness EN from glow plug 3 R 9003 at connector X 9036 Use a multimeter to check on the component for a grounded ...

Page 1014: ...sary 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display reading...

Page 1015: ...us of this fault A If the fault is present and active continue with Step 2 B If the fault is no longer present or in an inactive state the fault may be intermittent and not currently active Continue with Step 6 2 Check the glow plug for a short to ground condition Disconnect the engine harness EN from glow plug 2 R 9002 at connector X 9035 Use a multimeter to check on the component for a grounded ...

Page 1016: ...ry 6 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings ...

Page 1017: ...dition Disconnect the engine harness EN from the throttle valve actuator Z 9001 at connector X 9011 Disconnect the engine harness EN from the ECU A 9000 at connector X 9001 With the key in the ON position use a multimeter to perform the following voltage check on the engine harness EN side From To Value X 9011 pin 5 Chassis ground There should be no voltage A If there is voltage there is a short t...

Page 1018: ... is continuity there is a short to a voltage source in the throttle valve actuator Z 9001 position sensor signal circuit in the engine harness EN Use the appropriate service manual if necessary to locate and repair the shorted conductor B If there is no continuity leave connector X 9011 disconnected and continue to Step 6 6 Replace the throttle valve actuator Z 9001 Use the Electronic Service Tool...

Page 1019: ...ct the engine harness EN from the throttle valve actuator Z 9001 at connector X 9011 With the key in the OFF position use a multimeter to perform the following continuity check on the engine harness EN side From To Value X 9011 pin 5 Chassis ground There should be no continuity X 9011 pin 5 X 9011 pin 3 There should be no continuity X 9011 pin 5 X 9011 pin 2 There should be no continuity A If ther...

Page 1020: ... broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in the wiring concerned Operate the machine while you monitor the display A If you find damage or the display indicates other than normal display readings then repair the damage discov ered during the inspection or locate and repair the other than normal display conditio...

Page 1021: ... 9011 With the key in the OFF position use a multimeter to perform the following continuity check on the engine harness EN side From To Value X 9011 pin 2 X 9011 pin 6 There should be no continuity A If there is continuity there is a short circuit in the throttle valve actuator Z 9001 h bridge wiring Locate and repair the shorted conductor B If there is no continuity leave connector X 9011 disconn...

Page 1022: ...Electrical systems FAULT CODES Wiring harnesses Electrical schematic sheet 03 Engine sensors and fuel injection engine schematics 55 100 DP C 20 E 03 47866583_ 02 12 2015 55 12 55 DTC 301 ...

Page 1023: ... level or throttle valve actuator Z 9001 A If low voltage level faults are present resolve those faults and then return to this fault B If no low voltage level faults are present continue with Step 3 3 Check the ECU A 9000 for the appropriate software and re flash if necessary A If the fault has been resolved return the machine to service B If the fault has not been resolved escalate an ASIST conc...

Page 1024: ...resent or is in an inactive state the fault may be intermittent and not currently active Continue with Step 5 2 Check for other vehicle CAN faults Use the EST to determine if vehicle CAN faults exist A If other vehicle CAN faults do exist resolve the vehicle CAN faults then check to see that this fault is also resolved B If other vehicle CAN faults do not exist continue with Step 3 3 Check the ECU...

Page 1025: ...nded see the appropriate vehicle service manual and electrical schematics if necessary to locate and restore the termination resistance to the CAN circuit 5 Visually inspect the relevant harnesses and connectors for damage bent or dislocated pins corroded terminals or broken wires Verify that the connectors are fully installed Flex the harnesses involved to reveal intermittent breaks or shorts in ...

Page 1026: ...Fuel pressure relief valve is open 35 DTC 137 04 Fuel pressure relief valve is forced to open perform pressure increase 36 DTC 137 12 Averaged rail pressure is outside the expected tolerance range 37 DTC 141 02 Crankshaft speed sensor values are not plausible 38 DTC 141 04 Crankshaft speed sensor pattern is not plausible 40 DTC 143 02 Camshaft speed sensor values are not plausible 42 DTC 143 04 Ca...

Page 1027: ...2 DTC 199 02 Turbocharger boost pressure is higher than expected 97 DTC 199 02 Turbocharger boost pressure is higher than expected 96 DTC 1B1 03 CAN A Bus off failure 98 DTC 1B1 04 CAN A Bus off passive failure 100 DTC 1B5 02 CAN communication error between vehicle controller to ECU 102 DTC 1B7 02 CAN transmit error EEC1 message Electronic Engine Control 1 message Torque accelerator pedal engine s...

Page 1028: ...nsured 158 DTC 237 12 Quantity balance check if a successful PRV opening is ensured 157 DTC 238 03 Oil pressure switch active with engine off 159 DTC 238 04 Low oil pressure 161 DTC 256 03 Engine speed limitation via fuel injection cut off is active 163 DTC 259 03 Fuel metering unit is shorted to battery voltage at the low side 164 DTC 25A 03 Error in comparing energizing time to maximum value for...

Page 1029: ... a minimum limit 212 DTC 3E3 03 ECU internal failure Injection quantity correction 213 DTC 3E3 04 ECU internal failure Rail pressure plausibility 214 DTC 3E3 12 ECU internal failure Torque request comparison 215 DTC 3F6 03 DOC inlet temperature sensor voltage is higher than expected 216 DTC 3F6 04 DOC inlet temperature sensor voltage is lower than expected 218 DTC 426 03 Level 2 Monitoring Reporte...

Page 1030: ... Lambda sensor O2 value above maximum threshold 265 DTC 606 02 Lambda sensor virtual ground open circuit 267 DTC 607 03 Lambda sensor O2 calibrator too high error 269 DTC 607 04 Lambda sensor O2 calibrator too low error 270 DTC 609 02 ECU internal failure SPI chip error configuration 271 DTC 60A 04 Lambda sensor heater battery voltage too low 272 DTC 60B 03 Lambda sensor cell circuits short circui...

Page 1031: ...le valve actuator control circuit over load 300 DTC 78D 04 Throttle valve actuator control circuit supply voltage too low 302 DTC 7BA 02 Timeout Error of CAN Receive Frame CM1BC 303 47866583_ 02 12 2015 55 12 55 DTC 310 ...

Page 1032: ...47866583_ 02 12 2015 55 12 55 DTC 311 ...

Page 1033: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 1034: ...SERVICE MANUAL Platform cab bodywork and decals Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 90 ...

Page 1035: ...nts Platform cab bodywork and decals 90 90 100 Engine hood and panels 90 1 90 110 Operator platform less cab 90 2 90 116 Fenders and guards 90 3 90 118 Protections and footboards 90 4 47866583_ 02 12 2015 90 ...

Page 1036: ...Platform cab bodywork and decals 90 Engine hood and panels 100 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 90 1 90 100 1 ...

Page 1037: ...Contents Platform cab bodywork and decals 90 Engine hood and panels 100 SERVICE Hood Remove 3 Install 7 47866583_ 02 12 2015 90 1 90 100 2 ...

Page 1038: ...1 2 Disconnect the battery terminals NOTE Always disconnect the negative cable 1 first GNIL14TR00784AA 2 3 Unscrew hood mounting bracket bolts 1 and nuts 2 from engine frame GNIL14TR00856AA 3 4 Disconnect headlight harness connection and horn wirings 1 Unscrew gas strut bolt 2 and remove the front hood GNIL14TR00822AA 4 47866583_ 02 12 2015 90 1 90 100 3 ...

Page 1039: ...eel cover 1 GNIL14TR00512AA 5 6 Remove the steering wheel nut 1 GNIL14TR00846AA 6 7 Loosen the steering wheel securing nut and remove the steering wheel using tool number 82834312 and 9971375 GNIL14TR00704AA 7 8 Disconnect the wiring connection 1 GNIL14TR00711AA 8 47866583_ 02 12 2015 90 1 90 100 4 ...

Page 1040: ...he hand throttle knob GNIL14TR00706AA 10 11 Unscrew all the screws 1 of instrument panel GNIL14TR00707AA 11 12 Pull out the instrument panel from rear hood Discon nect all electric wire connections of the switches and hourmeter cable from instrument cluster Also remove fuel tank cap GNIL14TR00714AA 12 47866583_ 02 12 2015 90 1 90 100 5 ...

Page 1041: ...Remove pull to stop knob Unscrew all rear hood se curing screws and bolts GNIL14TR00849AA 13 14 Remove pull to stop knob and then centre panel Un screw all rear hood securing bolts lift and remove rear hood GNIL14TR00715AA 14 47866583_ 02 12 2015 90 1 90 100 6 ...

Page 1042: ...Platform cab bodywork and decals Engine hood and panels Hood Install For installation follow the removal process in reverse order 47866583_ 02 12 2015 90 1 90 100 7 ...

Page 1043: ...Index Platform cab bodywork and decals 90 Engine hood and panels 100 Hood Install 7 Hood Remove 3 47866583_ 02 12 2015 90 1 90 100 8 ...

Page 1044: ...Platform cab bodywork and decals 90 Operator platform less cab 110 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 90 2 90 110 1 ...

Page 1045: ...Contents Platform cab bodywork and decals 90 Operator platform less cab 110 SERVICE Platform Remove 3 Install 4 47866583_ 02 12 2015 90 2 90 110 2 ...

Page 1046: ... Operator platform less cab Platform Remove 1 Disconnect the wiring coupler of the operator s seat Loosen the bolts 1 and remove the operator s seat from the hydraulic lift assembly GNIL14TR04607AB 1 47866583_ 02 12 2015 90 2 90 110 3 ...

Page 1047: ...s Operator platform less cab Platform Install 1 Install the operator s seat on the hydraulic lift assembly and tighten the bolts 1 Connect the wiring coupler of the operator s seat GNIL14TR04607AB 1 47866583_ 02 12 2015 90 2 90 110 4 ...

Page 1048: ...Index Platform cab bodywork and decals 90 Operator platform less cab 110 Platform Install 4 Platform Remove 3 47866583_ 02 12 2015 90 2 90 110 5 ...

Page 1049: ...47866583_ 02 12 2015 90 2 90 110 6 ...

Page 1050: ...Platform cab bodywork and decals 90 Fenders and guards 116 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 90 3 90 116 1 ...

Page 1051: ...Contents Platform cab bodywork and decals 90 Fenders and guards 116 SERVICE Fenders and guards Remove 3 Install 5 47866583_ 02 12 2015 90 3 90 116 2 ...

Page 1052: ...08A DANGER Heavy objects Lift and handle all heavy components using lifting equipment with adequate capacity Always support units or parts with suitable slings or hooks Make sure the work area is clear of all bystanders Failure to comply will result in death or serious injury D0076A 1 Lift the front hood 2 Disconnect battery negative terminal 1 and insulate GNIL14TR00784AA 1 3 Disconnect the elect...

Page 1053: ...7 On RH side loosen two Allen screws one each on both the connectors of joystick cable Loosen two nuts on joystick connecting cable Remove connector pipe Remove the locking roll pin from the cable and remove the joystick cable GNIL14TR00764AA 6 8 Loosen bolts securing fenders Disconnect all the wirings Remove the fenders GNIL14TR00790AA 7 47866583_ 02 12 2015 90 3 90 116 4 ...

Page 1054: ...Platform cab bodywork and decals Fenders and guards Fenders and guards Install 1 For installation follow the reverse order of removal 47866583_ 02 12 2015 90 3 90 116 5 ...

Page 1055: ...Index Platform cab bodywork and decals 90 Fenders and guards 116 Fenders and guards Install 5 Fenders and guards Remove 3 47866583_ 02 12 2015 90 3 90 116 6 ...

Page 1056: ...Platform cab bodywork and decals 90 Protections and footboards 118 Workmaster 50 Workmaster 60 Workmaster 70 47866583_ 02 12 2015 90 4 90 118 1 ...

Page 1057: ...Contents Platform cab bodywork and decals 90 Protections and footboards 118 SERVICE Protections and footboards Remove 3 Install 5 47866583_ 02 12 2015 90 4 90 118 2 ...

Page 1058: ...Equipment PPE as indicated in this manual including protective goggles gloves and safety footwear Failure to comply could result in death or serious injury W0208A 1 Disconnect battery negative terminal 1 and insulate GNIL14TR00784AA 1 2 Disconnect the electrical couplings 1 GNIL14TR00797AA 2 3 Detach electric connections 1 between left and right hand side fenders GNIL14TR04012AB 3 47866583_ 02 12 ...

Page 1059: ... side of the tractor Remove both the brake pedal springs Remove parking brake linkages GNIL14TR00782AA 5 6 Loosen the bolts 1 and remove the footstep 2 GNIL14TR00797AA 6 7 Make sure that all the electrical couplings are discon nected Loosen all the bolts 1 securing foot boards on left hand side and right hand side fenders and transmis sion housing Remove the footboards GNIL14TR00767AA 7 47866583_ ...

Page 1060: ...Platform cab bodywork and decals Protections and footboards Protections and footboards Install 1 For installation follow the reverse order of removal 47866583_ 02 12 2015 90 4 90 118 5 ...

Page 1061: ...Index Platform cab bodywork and decals 90 Protections and footboards 118 Protections and footboards Install 5 Protections and footboards Remove 3 47866583_ 02 12 2015 90 4 90 118 6 ...

Page 1062: ...47866583_ 02 12 2015 90 4 90 118 7 ...

Page 1063: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

Page 1064: ...d Nut Socket Four Wheel Drive 25 1 21 380000268 Bevel Pinion Ring Nut Wrench Four Wheel Drive 25 1 24 380000257 Bevel Gear Pinion Splined Retainer Deep Socket Four Wheel Drive 25 1 24 380000252 Front Axle Ring Nut Wrench Four Wheel Drive 25 1 27 380000252 Front Axle Ring Nut Wrench Four Wheel Drive 25 1 28 380000257 Bevel Gear Pinion Splined Retainer Deep Socket Four Wheel Drive 25 1 28 380000265 ...

Page 1065: ...ng pinion Adjust 25 4 6 380000257 Bevel Gear Pinion Splined Retainer Deep Socket Final drive driving pinion Adjust 25 4 6 380000257 Bevel Gear Pinion Splined Retainer Deep Socket Final drive driving pinion Adjust 25 4 6 380001545 Slide Hammer Puller Adapter Non powered front axle Special tools 25 5 4 380001545 Slide Hammer Puller Adapter Non powered front axle Remove 25 5 9 9971349 Bevel wheel adj...

Page 1066: ...47866583_ 02 12 2015 ...

Page 1067: ...ay be reproduced NEW HOLLAND policy is one of continuous improvement and the right to change prices specification or equipment at any time without notices is reserved All data given in this publication is subject to production variations Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition For exact information about any particular...

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