New Holland WorkMaster 50 Service Manual
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New Holland WorkMaster 50 Service Manual

Tier 4b (final)
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Table of Contents

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SERVICE MANUAL
Workmaster
50 / Workmaster
60 /
™
™
Workmaster
70
™
Tier 4B (final)
Tractor
Part number 47866583
1
edition English
st
December 2015

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Do you have a question about the WorkMaster 50 and is the answer not in the manual?

Questions and answers

David King
April 20, 2025

Does any human answer these questions? I am desperately looking for the dipstick for the hydraulic/transmission fluid on a new Holland workmaster 60. There is no mention of it at any location in the owners manual. I have watched 236 videos one of a different new Holland model. All I’m trying to do is check the hydraulic fluid level and I have fought this for nearly a week. Does anybody know where this is on a workmaster 60?

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Summary of Contents for New Holland WorkMaster 50

  • Page 1 SERVICE MANUAL Workmaster 50 / Workmaster 60 / ™ ™ Workmaster ™ Tier 4B (final) Tractor Part number 47866583 edition English December 2015...
  • Page 2 SERVICE MANUAL Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 3 Link Product / Engine Product Market Product Engine North America R 753 IE4 Workmaster™ 50 Compact tractor, 2WD, 50 HP, TIER 4B (FINAL) Workmaster™ 50 Compact tractor, North America R 753 IE4 4WD, 50 HP, TIER 4B (FINAL) Workmaster™ 60 Compact tractor, North America R 753 IE4 2WD, 60 HP, TIER4B (FINAL)
  • Page 4 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.103] Crankshaft and flywheel.
  • Page 5 Rear axle system................ 27 [27.100] Powered rear axle..............27.1 [27.106] Rear bevel gear set and differential .
  • Page 6 [55.024] Transmission control system ............55.2 [55.048] Rear Power Take-Off (PTO) control system .
  • Page 7 47866583_ 02/12/2015...
  • Page 8 INTRODUCTION 47866583_ 02/12/2015...

  • Page 9: Table Of Contents

    Contents INTRODUCTION Foreword ..................3 Foreword Ecology and the environment .

  • Page 10: Foreword

    This repair manual provides the technical information needed to properly 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.

  • Page 11: Foreword Ecology And The Environment

    • Do not open the air-conditioning system yourself. It contains gases which should not be released into the atmos- phere. Your NEW HOLLAND dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.

  • Page 12: Advice

    INTRODUCTION Advice BT09A213 47866583_ 02/12/2015...

  • Page 13: International Symbols

    INTRODUCTION International symbols As a guide to the operation of the machine, various universal symbols have been utilized on the instruments, controls, switches, and fuse box. The symbols are shown below with an indication of their meaning. Thermostart Position Radio starting aid Control Alternator...

  • Page 14: Safety Rules

    INTRODUCTION Safety rules PRECAUTIONARY STATEMENTS Personal Safety Throughout this manual and on machine signs, you will find precautionary statements ("DANGER", "WARNING", and "CAUTION") followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them. Machine Safety The precautionary statement ("IMPORTANT") is followed by specific instructions.
  • Page 15 2. Use an approved roll bar and seat belt for safe operation. Overturning a tractor without a roll bar can result in death or injury. If your tractor is not equipped with a roll bar and seat belt, see your NEW HOLLAND Dealer.
  • Page 16 Always sit in the tractor seat when starting the engine or operating controls. Do not start the engine or operate controls while standing beside the tractor. Do not bypass the neutral start switches. Consult your NEW HOLLAND Dealer if your neutral start controls malfunction. Use jumper cables only in the recommended manner. Improper use can result in tractor runaway.
  • Page 17 Wipe up spilled fuel immediately. Always tighten the fuel tank cap securely. 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. Keep equipment clean and properly maintained.

  • Page 18: Basic Instructions Hardware

    Plating Hardware used on NEW HOLLAND balers is plated with zinc chromate (gold color). Gold colored hardware has different torquing requirements from unplated or zinc plated (silver color) hardware because of the difference in the coefficient of friction of the plating material.

  • Page 19: General Specification - Biodiesel Fuels

    ASTM D6751. NOTICE: It is imperative that you check which blend is approved for your engine with your NEW HOLLAND dealer. Be aware that the use of Biodiesel Fuel that does not comply with the Standards mentioned above could lead to severe damage to the engine and fuel system of your machine.
  • Page 20 SERVICE MANUAL Engine Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 21 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.103] Crankshaft and flywheel.
  • 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 .
  • Page 24 Engine - Engine and crankcase Engine - Remove WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 25 Engine - Engine and crankcase 4. Unscrew the hood mounting bracket bolts (1) and nuts (2) from engine frame. GNIL14TR00856AA 5. Disconnect headlight and horn harness connection (1). 6. Unscrew gas strut bolt (2) and remove the front hood. GNIL14TR00822AA 7.
  • Page 26 Engine - Engine and crankcase 8. Loosen the silencer mounting bolts (1) and (2). 9. Remove the silencer (3). GNIL14TR00611AA 10. Disconnect the electric connection (1) to starter motor. GNIL14TR00713AA 11. Disconnect the fuel supply and return lines. GNIL14TR00712AA 47866583_ 02/12/2015 10.1 [10.001] / 5...
  • Page 27 Engine - Engine and crankcase 12. Remove the steering wheel cover (1). GNIL14TR00512AA 13. Remove the steering wheel securing nut (1). GNIL14TR00846AA 14. Remove the steering wheel using tool number 380001672, and 380003008. GNIL14TR00704AA 15. Disconnect the wiring (1) on the steering column. GNIL14TR00711AA 47866583_ 02/12/2015 10.1 [10.001] / 6...
  • Page 28 Engine - Engine and crankcase 16. Loosen the bolt (1) and remove the shuttle lever. GNIL14TR00705AA 17. Loosen the screw (1) and remove the hand throttle knob. GNIL14TR00706AA 18. Unscrew all the screws securing instrument panel to the rear hood. GNIL14TR00707AA 19.
  • Page 29 Engine - Engine and crankcase 21. Remove pull to stop knob and then centre panel. Unscrew all rear hood securing bolts and screws on rear hood. GNIL14TR00849AA 22. Lift and remove the rear hood. GNIL14TR00715AA 23. Disconnect the diesel overflow pipe (1) on the fuel tank.
  • Page 30 Engine - Engine and crankcase 26. Loosen the bolts (1) and release the fuel tank strap. NOTE: It is advisable to drain diesel from fuel tank if tank is more than half filled. GNIL14TR00709AA 27. Loosen the bolts (1) and remove the wiring couplers at the rear of fuel tank.
  • Page 31 Engine - Engine and crankcase 32. Loosen the bolts (1) securing cover of the SCR (Se- lective Catalytic Reduction) assembly to the fuel tank support plate. GNIL14TR00857AA 33. Remove all the bolts securing the fuel tank base plate to the clutch housing. 34.
  • Page 32 Engine - Engine and crankcase 37. Loosen the set screws and remove the hydraulic filter. GNIL14TR00728AA 38. Disconnect the power steering hoses on the steering motor. GNIL14TR00740AA 39. Loosen the bolts (1) of the 4WD shaft cover. GNIL14TR00823AA 40. Remove the circlip and slide the coupler (1) backward. GNIL14TR04359AB 47866583_ 02/12/2015 10.1 [10.001] / 11...
  • Page 33 Engine - Engine and crankcase 41. Position splitting trolley, special tool number 292320, with engine supports in position. 42. Block front wheels at the front and back using suitable wedges. GNIL14TR04779AA 43. Support the engine at the back of the front axle. 44.
  • Page 34 Engine - Engine and crankcase Separating front axle from engine With engine previously separated from centre housing 47. Remove the electrical couplers (1) from Engine Con- trol Unit (ECU) and (2) for rear lamps, flasher unit, fuse box etc. GNIL14TR00757AA 48.
  • Page 35 Engine - Engine and crankcase 51. Loosen the clamp (1) on the air inlet hose. 52. Loosen the bolt (2) and remove the air cleaner assem- bly. GNIL14TR00720AA 53. Loosen the bolts and remove the air cleaner mounting bracket. GNIL14TR00860AA 54.
  • Page 36 Engine - Engine 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 ............... . Engine - Remove .
  • 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 .
  • Page 40 Engine - Crankshaft and flywheel Engine flywheel - Remove WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 41 Engine - Crankshaft and flywheel 5. Remove the bolts (1) and take out the flywheel from the main clutch housing. GNIL14TR00770AA Clutch housing separation from the engine (if necessary) 6. Place a suitable support. Remove the bolts (1) and separate the clutch housing. GNIL14TR00771AA 47866583_ 02/12/2015 10.2 [10.103] / 4...
  • Page 42 Engine - Crankshaft and flywheel Engine flywheel - Inspect 1. Inspect the ring gear for cracked, broken, chipped, or worn gear teeth. If found damaged, replace the ring gear. 2. If necessary, remove the starter ring gear using a ham- mer and chisel to crack the ring gear.
  • Page 43 Index Engine - 10 Crankshaft and flywheel - 103 Engine flywheel - Inspect ............. . . Engine flywheel - Remove .
  • 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 .
  • Page 46 Engine - Air cleaners and lines Air cleaner - Remove NOTE: It is not necessary to remove the complete air cleaner body, as described below, to service the air cleaner elements. 1. Lift the front hood. 2. Loosen the clamp (1) of air cleaner hose. Remove the air cleaner hose.
  • Page 47 Engine - Air cleaners and lines Air cleaner - Disassemble NOTE: The air cleaner assembly can be serviced on 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).
  • Page 48 Engine - Air cleaners and lines Air cleaner - Inspect 1. Examine the element for damage by placing a light inside the element.. Discard the element if pin pricks of light can be seen or there are areas where paper appears thin.
  • Page 49 Engine - Air cleaners and lines Air cleaner - Cleaning WARNING Chemical hazard! Stop the fan before you open the lid. Avoid exposure to airborne chemicals. Dust and fumes will be exhausted if you open the tank lid while the tank is pressurized. Chemicals may cause eye, skin, or breathing problems.
  • Page 50 Engine - Air cleaners and lines Air cleaner - Replace 1. The inner element to be removed only at the 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.
  • Page 51 Engine - 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 Index Engine - 10 Air cleaners and lines - 202 Air cleaner - Assemble ..............Air cleaner - Cleaning .
  • 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 .
  • Page 56 Engine - Fuel filters Pre-filter - Remove 1. Lift the front hood. 2. Remove the electrical connections on the fuel prefilter. GNIL14TR00737AA 3. Disconnect all the fuel lines on the fuel prefilter. GNIL14TR00712AA 4. Loosen the bolts (1) and remove the fuel prefilter. GNIL14TR00862AA 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 ............... Pre-filter - Remove .
  • 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 .
  • Page 62 Engine - Fuel tanks Fuel cooler - Remove 1. Lift the front hood. 2. Remove the battery. See Battery - Remove (55.302). 3. Disconnect the fuel pipes (1) on the fuel cooler. GNIL14TR00703AA 4. 1. Loosen all the bolts (1). 2.
  • Page 63 Engine - Fuel tanks Fuel cooler - Install 1. Install the fuel cooler (1) and tighten the bolts (2). GNIL14TR00703AA 2. Connect the fuel pipes (1) on the fuel cooler. GNIL14TR00703AA 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 ..............Fuel cooler - Remove .
  • 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 .
  • Page 68 Engine - Aftercooler Aftercooler - Remove 1. 1. Lift the front hood. 2. Disconnect the negative terminal (1) of the battery. GNIL14TR00784AA 2. 1. Loosen the bolt (1). 2. Remove the steering oil reservoir (2). GNIL14TR00759AA 3. 1. Disconnect the hose from the radiator coolant reser- voir.
  • Page 69 Engine - 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 47866583_ 02/12/2015 10.6 [10.310] / 4...
  • Page 70 Engine - Aftercooler Aftercooler - Install 1. 1. Install the after cooler (1) on the mounting bracket and tighten the bolts (2). 2. Connect the inlet hose (3) and outlet hose (4) of the radiator. GNIL14TR00702AA 2. 1. Install the Engine Control Unit (ECU) and tighten the bolts (1).
  • Page 71 Engine - Aftercooler 5. Connect the negative terminal (1) of the battery. GNIL14TR00784AA 47866583_ 02/12/2015 10.6 [10.310] / 6...
  • Page 72 Index Engine - 10 Aftercooler - 310 Aftercooler - Install ..............Aftercooler - Remove .
  • 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 .
  • Page 76 Engine - Engine cooling system Radiator - Remove 1. Lift the front hood. 2. Disconnect the wiring couplers on the ECU (Engine Control Unit) bracket and fuse box. Remove the ECU Bracket, steering oil reservoir, intercooler and fuel cooler. See Aftercooler - Remove (10.310) and Fuel cooler - Remove (10.216).
  • Page 77 Engine - Engine cooling system 6. Remove all the hoses from the radiator GNIL14TR00717AA 7. Loosen and remove all the radiator mounting bolts. Re- move the radiator from the tractor. GNIL14TR00761AA 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 ............... Radiator - Remove .
  • Page 80 47866583_ 02/12/2015 10.7 [10.400] / 7...
  • Page 81 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 82 SERVICE MANUAL Clutch Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 83 Contents Clutch - 18 [18.100] Clutch mechanical release control ........... 18.1 [18.110] Clutch and components .
  • 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 .
  • Page 86 Clutch - Clutch mechanical release control Clutch mechanical release control - Remove 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, including protective goggles, gloves, and safety footwear.
  • Page 87 Clutch - Clutch mechanical release control 8. Remove split pin (1). 9. Disconnect linkage (2) from clutch cross shaft. GNIL14TR00781AA 10. Similarly remove brake pedal spring (2) and discon- nect all the linkages. GNIL14TR00782AA 11. Jack-up rear left-hand side of tractor and remove left-hand side rear wheel.
  • Page 88 Clutch - Clutch mechanical release control Power Take-Off (PTO) clutch lever removal To remove the Power Take-Off (PTO) clutch lever (1) proceed as follows:- 1. Remove pin (1) by releasing lock plate and dis- connect linkage between Power Take-Off (PTO) clutch lever and Power Take-Off (PTO) clutch cross shaft.
  • Page 89 Clutch - Clutch mechanical release control 2. Slide out both transmission and Power Take-Off (PTO) clutch release bearings (1) and (2) from the shaft. GNIL14TR04674AB 3. Loosen the Power Take-Off (PTO) clutch fork lock screw (1). GNIL14TR04675AB 4. Pull out the Power Take-Off (PTO) cross shaft (1) from left hand-side of transmission housing and retrieve fork from the housing.
  • Page 90 Clutch - Clutch mechanical release control Clutch mechanical release control - Install Reassemble the clutch mechanical release control. Take care of the following: 1. Reassembly follows the disassembly procedure in re- verse. 2. Make sure that the lock clips are properly seated on the clutch release forks.
  • Page 91 Clutch - Clutch mechanical release control Clutch mechanical release control - Adjust Clutch pedal free play should be 30.00 - 45.00 mm (1.18 - 1.77 in). To adjust the clutch pedal free play proceed as follows: GNIL14TR04687AA 1. Remove the split pin (1) and disconnect the linkage. 2.
  • Page 92 Clutch - Clutch mechanical release control 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.
  • Page 93 Index Clutch - 18 Clutch mechanical release control - 100 Clutch mechanical release control - Adjust ..........Clutch mechanical release control - Install .
  • 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 Contents Clutch - 18 Clutch and components - 110 TECHNICAL DATA Clutch General specification ............... 3 Torque .
  • Page 96 Clutch - Clutch and components Clutch - General specification Type Dry plate torsion springs Control Mechanical pedal for transmission Hand lever for PTO Release mechanism Diaphragm type Plate material Cerametallic Plate thickness 7.50 - 8.10 mm (0.30 - 0.32 in) Plate with pressure springs Tangential springs Clutch - Torque...
  • Page 97 Clutch - Clutch and components GNIL14TR00801GA Clutch - Special tools Tool Description Tool Number 380000612 Clutch centralizer and finger height setting gauge 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...
  • Page 98 Clutch - Clutch and components GNIL14TR04659GB 47866583_ 02/12/2015 18.2 [18.110] / 5...
  • Page 99 Clutch - Clutch and components Clutch - Dynamic description The clutch system is double clutch mechanical type. It includes two dry clutch discs with non-asbestos, organic ma- terial pads. One clutch disc is to connect transmission to engine and another for connecting PTO directly to engine, independent of transmission.
  • Page 100 Clutch - Clutch and components Clutch - Sectional view GNIL14TR00802GA (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 (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 Clutch - Clutch and components Clutch - Remove WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 103 Clutch - Clutch and components Clutch - Disassemble WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 104 Clutch - Clutch and components 5. Loosen lock nut (1). GNIL14TR04698AB 6. Remove transmission clutch pressure plate (1). GNIL14TR04699AB 7. Remove transmission clutch disc (1) from the housing. GNIL14TR04700AB Release fingers disassembly 8. Push out the pin (1) from the housing and retrieve the spring (2).
  • Page 105 Clutch - Clutch and components 9. Remove release fingers from the housing. GNIL14TR04703AA 47866583_ 02/12/2015 18.2 [18.110] / 12...
  • Page 106 Clutch - Clutch and components Clutch - Inspect 1. Check clutch driven discs for wear and replace if rivets (2) are near or flush with top facing. 2. Discs are also to be replaced if the organic facings are found to be soaked with oil. 3.
  • Page 107 Clutch - Clutch and components See 1. • Fly wheel (1) under cut - ‘A’ = 2.000 mm (0.079 in) • Power Take-Off (PTO) clutch pressure plate (2) thickness - ‘B’ = 22.000 mm (0.866 in) • Transmission clutch pressure plate (3) thickness - ‘C’ = 24.000 mm (0.945 in) •...
  • Page 108 Clutch - Clutch and components Clutch - Assemble Re-assembly follows disassembly procedure in reverse order. See Clutch - Disassemble (18.110) . 1. Position disc springs (1) correctly and lock-ring (2) on transmission pressure plates as shown in 1. GNIL14TR04706AB 2. Use special tool number 380000612, and centralize the clutch discs.
  • Page 109 Clutch - Clutch and components Clutch - Adjust For correct function of clutch release mechanism, the release fingers must be set at the distances D - 96 mm (4 in) and D1 - 121 mm (5 in) relative to flywheel face for transmission clutch and Power Take-Off (PTO) clutch respectively.
  • Page 110 Clutch - Clutch and components Clutch - Service instruction WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 111 Clutch - Clutch and components Clutch control mechanism - Remove WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 112 Clutch - Clutch and components 6. Unscrew bolts as shown in figure and remove top cover (1). GNIL14TR04682AB 7. Remove lock (1) as shown in figure. Use plastic ham- mer to push out the shaft. The shaft will come out to- ward gearbox side.
  • Page 113 Clutch - Clutch and components Clutch - Troubleshooting Problem Possible Cause Correction Clutch slips Clutch disc, pressure plate and/or flywheel Replace clutch disc; replace clutch if nec- wear. essary and grind the flywheel. Damaged or bent or broken fingers. Replace finger assembly. Oil or grease on friction material.
  • Page 114 Index Clutch - 18 Clutch and components - 110 Clutch - Adjust ............... . . Clutch - Assemble .
  • Page 115 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 116 SERVICE MANUAL Transmission Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 117 Contents Transmission - 21 [21.114] Mechanical transmission ............. 21.1 [21.130] Mechanical transmission external controls.
  • Page 118 Transmission - 21 Mechanical transmission - 114 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 21.1 [21.114] / 1...
  • Page 119 Contents Transmission - 21 Mechanical transmission - 114 TECHNICAL DATA Mechanical transmission General specification ............... 3 Torque .
  • Page 120 Transmission - Mechanical transmission Mechanical transmission - General specification Gear box type Constant mesh Range gears Constant mesh Forward-reverse Mechanical Synchromesh Shuttle Lubrication Transmission oil capacity APGL4SAE 20W30 23 L (6 US gal) for 2WD (Two Wheel Drive) and 25.0 L (6.6 US gal) for 4WD (Four Wheel Drive) Rear Tire Size 13.6-28...
  • Page 121 Transmission - Mechanical transmission GNIL14TR00824GA 47866583_ 02/12/2015 21.1 [21.114] / 4...
  • Page 122 Transmission - Mechanical transmission GNIL14TR00828GA Mechanical transmission - Sealing Description Sealant specification Rear axle to transmission housing (S1) ® 518™ OCTITE Gear shift lever cover (S2) ® 518™ OCTITE Power Take-Off (PTO) cover plate (S3) ® 518™ OCTITE Crown wheel bolts (S4) ®...
  • Page 123 Transmission - Mechanical transmission GNIL14TR04003GB Mechanical 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 Transmission - Mechanical transmission Mechanical transmission - Sectional view GNIL14TR00826FA Drive shaft 1st - 2nd Synchrokit Range shaft 10. 3rd - 4th Synchrokit Power Take-Off (PTO) input shaft 11. Hi - Lo gear coupler 1st gear 12. Low gear on range shaft 2nd gear 13.
  • Page 125 Transmission - Mechanical transmission GNIL14TR00827GA 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.
  • Page 126 Transmission - Mechanical transmission Mechanical transmission - Overview 8+8 Synchro shuttle The transmission has eight forward and eight reverse gears. WARNING Avoid injury! Always do the following before lubricating, maintaining, or servicing the ma- chine. 1. Disengage all drives. 2. Engage parking brake. 3.
  • Page 127 Transmission - Mechanical transmission GNIL14TR04107FB Main gear lever (1st/2nd & 3rd/4th) PTO 540 Range selector lever (H/L) High PTO Coupler Reverse The speeds are shifted by meshing gears 1st (4), 2nd (5), 3rd (6), and 4th (7) in succession with the gearbox driven shaft.
  • Page 128 Transmission - Mechanical transmission 8 + 8 Synchro shuttle The synchro shuttle transmission is ideal for application which require frequent changes of direction. The oper- ator has to press clutch pedal and move shuttle lever to change direction of travel. Shift lever (1) to front for for- ward and rear to get reverse direction.
  • Page 129 Transmission - Mechanical transmission Drive shaft - Service instruction NOTE: Please read this carefully before starting assembly or disassembly operations. Precaution at flange and tool ends While hammering at flange and tool ends during re- moval or installation, attention must be paid to the vari- ous phases.
  • Page 130 Transmission - Mechanical transmission Bearings Use correct pullers for bearings removal. Clean, lubricate and inspect well before reassembling the bearings. The spiral elastic pins do not need such adjustment. Sealing Use sealants as specified. ensure that parts to be sealed are clean, dry and grease free. Oil drain Before disassembly oil should be drained out from the group.
  • Page 131 Transmission - Mechanical transmission Mechanical transmission - Remove WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 132 Transmission - Mechanical transmission 3. Disconnect the clutch linkages and the brake linkages. GNIL14TR00766AA 4. Remove both the left-hand and right-hand side wheels. GNIL14TR04016AB 5. Loosen the bolts (1) and remove fenders from both sides. Drain oil from transmission housing. GNIL14TR00790AA 6.
  • Page 133 Transmission - Mechanical transmission 8. Remove the ROPS (Roll Over Protection Structure) from the tractor. GNIL14TR00865AA 9. Place splitting trolley (special tool number: 292320) (1) under the tractor. Place a suitable stand under both side of the final drive housing. 10.
  • Page 134 Transmission - Mechanical transmission 13. Loosen the bolt (1) as shown in figure before separat- ing the transmission housing from clutch housing. GNIL14TR04024AB 14. Separate the clutch and transmission housing. GNIL14TR04128AA 15. Wrap chain or nylon rope on the final drive housing and connect it to a hoist.
  • Page 135 Transmission - Mechanical transmission Mechanical transmission - Disassemble – Intermediate plate WARNING 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 could result in death or serious injury.
  • Page 136 Transmission - Mechanical transmission 5. Remove the snap ring (2) securing the reverse drive gear. 6. Remove the reverse drive gear (1) from drive shaft. GNIL14TR04147AB 7. Unscrew the reverse intermediate gear shaft locking screw (1) with a screw driver (2). 8.
  • Page 137 Transmission - Mechanical transmission 11. Remove all the bolts (1) securing the intermediate plate. GNIL14TR04138AB 12. Remove the intermediate plate (1) along with the bear- ings. GNIL14TR04139AB 13. Remove the ball bearings from the intermediate plate by expanding the retaining rings (1). GNIL14TR04140AB 47866583_ 02/12/2015 21.1 [21.114] / 20...
  • Page 138 Transmission - Mechanical transmission 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 Transmission - Mechanical transmission Mechanical transmission - Assemble – Intermediate plate WARNING 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 could result in death or serious injury.
  • Page 140 Transmission - Mechanical transmission 5. Secure the driven shaft bearing with the snap ring (1). GNIL14TR04144AB 6. Install the spacer (1), needle bearing (2) and reverse intermediate gear pin (3) along with the reverse inter- mediate gear (4). GNIL14TR04145AB 7. Use thread locker L ®...
  • Page 141 Transmission - Mechanical transmission 10. Install all the shift rails shift gates and shift forks after installing the springs (1) and detent balls (2). GNIL14TR04148AB 11. Install all roll pins to shift rails along with springs and detent balls. NOTE: Install the detent balls and springs where shown (1) and (2).
  • Page 142 Transmission - Mechanical transmission Mechanical transmission - Install NOTE: Before assembling housings covers and support, thoroughly clean and degrease mating surfaces and apply a 2.000 mm (0.079 in) bead of L ® 518™ sealant. OCTITE 1. Use a suitable lifting device to lift and install the final drive housing.
  • Page 143 Transmission - Mechanical transmission 9. Install the operator's seat onto the hydraulic housing. Connect the wiring. GNIL14TR04021AB 10. Connect all the hydraulic lines. 11. Install the ROPS to the axle housings. Secure using the bolts and nuts (1). GNIL14TR04017AB 12. Install the rear fenders (1). GNIL14TR00790AA 13.
  • Page 144 Transmission - Mechanical transmission 16. Secure the footrest (1) to the fender and transmission housing. GNIL14TR04162AB 17. Connect the clutch linkage (1). NOTE: Check the clutch pedal free play and adjust as nec- essary. NOTE: Connect the brake linkage rods to the brake pedals. GNIL14TR04164AB 18.
  • Page 145 Transmission - Mechanical transmission 20. Connect the negative battery cable (1) to the negative battery terminal. GNIL14TR00784AA GNIL14TR04168GB 47866583_ 02/12/2015 21.1 [21.114] / 28...
  • Page 146 Transmission - Mechanical transmission Mechanical transmission - Troubleshooting Problem Possible Cause Correction Noisy operation with Input and output shaft support bearing mis- Remove transmission housing and adjust range in neutral and main adjusted. bearings. lever engaged Remove housing, overhaul transmission Failed or defective inner component.
  • Page 147 Index Transmission - 21 Mechanical transmission - 114 Drive shaft - Service instruction ............Mechanical transmission - Assemble –...
  • 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 Contents Transmission - 21 Mechanical transmission external controls - 130 SERVICE Mechanical transmission external controls Remove ................. . 3 Adjust .
  • Page 150 Transmission - Mechanical transmission external controls Mechanical transmission external controls - Remove Transmission 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.
  • Page 151 Transmission - Mechanical transmission external controls Mechanical transmission external controls - Adjust Shuttle interlock cable 1. Measure dimension (A) at cable end as shown in figure 1. (Top of nut to bottom of threads). The desired length of (A) is approximately 26.000 mm (1.024 in), adjust if required.
  • Page 152 Transmission - Mechanical transmission external controls Transmission control levers - Disassemble WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 153 Transmission - Mechanical transmission external controls 4. Remove the roll pin (1) and remove the linkage (2). GNIL14TR00807AA 5. Loosen the bolt and remove the yoke (1). GNIL14TR00809AA 6. Remove the split pins (1) and take out pin (2) to remove range gear selector lever (3).
  • Page 154 Transmission - Mechanical transmission external controls 8. Remove the washer (1) and linkage (2). NOTE: Take out springs 2 numbers from the range lever. GNIL14TR04094AB 9. Remove the expansion plug (1) from the shifter cover housing as shown. GNIL14TR04095AB 10. Remove the roll pin (1) from the shaft (2). Remove the fork (3).
  • Page 155 Transmission - Mechanical transmission external controls Transmission control levers - Install Assemble the levers in the cover plate and reinstall the cover plate on the transmission housing. Observe the following. 1. Inspect the rubber boot (1) for cracks or damage, re- place if necessary.
  • Page 156 Index Transmission - 21 Mechanical transmission external controls - 130 Mechanical transmission external controls - Adjust ......... Mechanical transmission external controls - Remove .
  • 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 Transmission - Mechanical transmission internal components Transmission internal parts - Install Transmission rails and fork To install the shift rail and shift forks follow the proce- dure as mentioned below. 1. Insert the bottom shift rail, (1), and 1st/2nd gearshift fork.
  • Page 161 Transmission - Mechanical transmission internal components 4. After fitting reverse rail insert ball (1), applying some grease in the housing. 20097886 5. Insert the rail (1), of 3rd/4th with gate (2), passing through fork (3), of 3rd/4th gear as shown in 5. Insert gate of 1st/2nd rail shaft on the notch of 1st/2nd gear fork.
  • Page 162 Transmission - Mechanical transmission internal components 9. After fitting reverse 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.
  • Page 163 Index Transmission - 21 Mechanical transmission internal components - 140 Transmission internal parts - Install Transmission rails and fork ......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 Contents Transmission - 21 Gearbox internal components - 145 SERVICE Gearbox internal components Remove ................. . 3 Inspect .
  • Page 166 Transmission - Gearbox internal components Gearbox internal components - Remove Transmission synchronizer kit and cluster gear 1. Remove the split pins to release the link. 2. Remove the circlip lock (1). GNIL14TR04196AB 3. Remove the shuttle wire (1) as shown. GNIL14TR04197AB 4.
  • Page 167 Transmission - Gearbox internal components 5. Remove the shuttle detent bolt from the left-hand side of the clutch housing. GNIL14TR04199AB 6. Remove the spring (1) from the hole in the clutch hous- ing. GNIL14TR04200AB 7. Remove the detent ball (1) from the hole in the clutch housing.
  • Page 168 Transmission - Gearbox internal components 12. Remove the cluster gear shaft (1) from the ball bear- ing. 13. Remove the ball bearing (2) from the cluster gear shaft (1). GNIL14TR04203AB 14. Remove the external circlip (1) from the groove of the input shaft.
  • Page 169 Transmission - Gearbox internal components 19. Remove the synchronizer kit (1) shift fork (2) and rail (3). GNIL14TR04207AB 20. Remove the reverse gear (1). GNIL14TR04208AB 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).
  • Page 170 Transmission - Gearbox internal components Gearbox internal components - Inspect 1. Wash all parts in a suitable cleaning solution and allow to air dry. 2. Inspect the bearings for excess wear, score marks , discoloration from overheating or other damage. Ro- tate the bearings by hand and check for any roughness.
  • Page 171 Transmission - Gearbox internal components Gearbox internal components - Install 1. Place the oil trench plate (1) on the housing surface and tighten the bolts (2) with washer (3) to 25.5 N·m (18.8 lb ft). 2. Install the ball bearing (4) from the rear of the clutch housing.
  • Page 172 Transmission - Gearbox internal components 11. Install the shuttle coupler gear assembly (1) over the input shaft. 12. Secure the shuttle coupler gear on the input shaft with the external snap ring (2). GNIL14TR04215AB 13. Press the ball bearing (1) into the cluster gear shaft (2).
  • Page 173 Transmission - Gearbox internal components 21. Insert the detent ball (1) in front of the spring. GNIL14TR04219AB 22. Insert the spring (1) into the clutch housing. 23. Install the shuttle detent bolt to the left-hand side of the clutch housing. GNIL14TR04220AB 24.
  • Page 174 Transmission - Gearbox internal components 26. Attach the cable on the linkage and secure with the snap ring (1). 27. Attach the linkage to the shaft link rod. Secure using the pin and cotter pin. GNIL14TR04223AB Synchro shuttle rails and fork 28.
  • Page 175 Transmission - Gearbox internal components 32. 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 shaft fit fork for 3rd/4th and insert reverse rail (3), passing through fork of 3rd/4th gear.
  • Page 176 Transmission - Gearbox internal components 37. Insert the 1st/2nd rail (2) passing thru gate as shown in figure 18. NOTE: Keep grooves of rails upward to make easy fitment of balls and springs. 38. Insert the ball and pin (1) after removing neutral safety switch for Hi/Low rail then fit neutral safety switch and tighten it.
  • Page 177 Transmission - Gearbox internal components Drive shaft - Remove 1. Remove the drive shaft (1) 3rd gear drive gear (2) and 3rd/4th gear coupler (3) as a assembly from the trans- mission housing. NOTE: 1st and 2nd gear are a integral part of the drive shaft.
  • Page 178 Transmission - Gearbox internal components 5. Remove the driven shaft (1) from the housing. NOTE: 3rd and 4th gears are a integral part of the driven shaft. 6. Clean and inspect the gears and hub for excess wear, chipped gear teeth, cracks or any other damage. Re- place as necessary.
  • 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 47866583_ 02/12/2015 21.4 [21.145] / 16...
  • Page 180 Transmission - Gearbox internal components Drive shaft - Disassemble 1. Remove the snap ring (1) from the drive shaft to remove the hub along with coupler. GNIL14TR04179AB GNIL14TR04180AA 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.
  • Page 181 Transmission - Gearbox internal components Drive shaft - Inspect 1. Wash all parts in a suitable 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.
  • Page 182 Transmission - Gearbox internal components Driven shaft - Remove 1. Remove the bottom shift rail (1). NOTE: The bottom shift rail has a M12 plug (2) that must be removed from the front of the housing. GNIL14TR04169AB 2. Remove the 1st gear (1) off the synchromesh driven shaft.
  • Page 183 Transmission - Gearbox internal components 5. Remove the 2nd gear (1) from driven shaft. GNIL14TR04173AB 47866583_ 02/12/2015 21.4 [21.145] / 20...
  • Page 184 Transmission - Gearbox internal components Driven shaft - Disassemble Dismantling on bench 1. Remove the snap ring (1) to remove the high gear (2) and bearing (3) from the synchromesh driven shaft. GNIL14TR04182AB NOTE: 3rd and 4th gear are a integral part of the driven shaft (1).
  • Page 185 Transmission - Gearbox internal components Driven shaft - Inspect 1. Wash all parts in a suitable cleaning solution and allow to air dry. 2. Inspect the bearing for excess wear, score marks, dis- coloration from overheating or other damage. Rotate the bearing by hand and check for any roughness while turning.
  • Page 186 Transmission - Gearbox internal components Driven shaft - Install Transmission drive and driven shafts NOTE: Before assembly carefully check gears needle bearing snap rings etc. and replace if found faulty. 1. Fit the oil connector (1) between driven shaft and pin- ion keeping larger diameter towards driven shaft before fitting driven shaft on pinion.
  • Page 187 Transmission - Gearbox internal components 5. Install shims and synchronizer ring on the 4th gear. GNIL14TR04188AB 6. Instal 3rd gear with synchronizer on drive shaft (1) and retain with snap ring (2). GNIL14TR04189AB 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).
  • Page 188 Transmission - Gearbox internal components 9. Install 2nd gear onto the synchromesh driven shaft and secure 2nd gear with a snap ring (1). GNIL14TR04192AB 10. Install the hub (1) 1st/2nd gear coupler (2) onto the driven shaft and insert the shift fork (3) onto the cou- pler.
  • Page 189 Index Transmission - 21 Gearbox internal components - 145 Drive shaft - Disassemble ............. . . Drive shaft - Inspect .
  • 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 .
  • Page 192 Transmission - Dropbox Dropbox - Remove 1. After removing the drive shaft, drain the oil from the tractor transmission. See Drive shaft - Remove (23.314) for the drive shaft removal. 2. Detach the hand lever vertical rod (1) from the drop box control lever.
  • Page 193 Transmission - Dropbox Dropbox - Disassemble 1. Use a punch to remove the roll pin (1) from the drop box (2) and idler gear shaft (3). 2. Push the idler gear shaft (3), forward out of the drop box (2) and remove the idler gear (4), spacers (5), and needle bearing (6) from the drop box.
  • Page 194 Transmission - Dropbox Dropbox - Assemble 200900125 1. Install rear bearing (1) into the drop box. 2. Install inner change lever (2) with O-ring (3) into the drop box. 3. Install pad (4) onto the changing lever. 4. Install detent plunger (5), plunger spring (6), plug (7) with sealing washer (8).
  • Page 195 Transmission - Dropbox Dropbox - Install 200900127 1. Make sure that the two locating dowel pins (1) are in- stalled in the drop box. 2. Place a bead of gasket eliminator 518 onto the mount- ing surface of the transfer box. 3.
  • Page 196 Index Transmission - 21 Dropbox - 200 Dropbox - Assemble ..............Dropbox - Disassemble .
  • Page 197 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 198 SERVICE MANUAL Four-Wheel Drive (4WD) system Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 199 Contents Four-Wheel Drive (4WD) system - 23 [23.314] Drive shaft................23.1 47866583_ 02/12/2015...
  • 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 .
  • Page 202 Four-Wheel Drive (4WD) system - Drive shaft Drive shaft - Remove 1. Loosen the bolts (1) on both the ends of the Four-Wheel Drive (4WD) shaft guard and remove the 4WD shaft guard. NOTE: The drive shaft guard can be separated into two sections.
  • Page 203 Four-Wheel Drive (4WD) system - Drive shaft Drive shaft - Install GNIL15TR01128FA 1. Tighten the bolts (1) on the center mounting bracket of the Four-Wheel Drive (4WD) shaft. GNIL15TR01129AA 2. Engage the spline coupler (2), figure 1, on the Power Take-Off (PTO) shaft of the front axle and the 4WD shaft.
  • Page 204 Four-Wheel Drive (4WD) system - Drive shaft 4. Seat the retaining rings (8), figure 1, on the front axle PTO shaft and 4WD shaft. 5. Seat the retaining ring (1) on the PTO shaft of the drop box. GNIL15TR01130AA 6. Slide the spline coupler (1) toward the drop box. 7.
  • 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 47866583_ 02/12/2015 23.1 [23.314] / 6...
  • Page 206 Index Four-Wheel Drive (4WD) system - 23 Drive shaft - 314 Drive shaft - Install ..............Drive shaft - Remove .
  • Page 207 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 208 SERVICE MANUAL Front axle system Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 209 Contents Front axle system - 25 [25.100] Powered front axle ..............25.1 [25.102] Front bevel gear set and differential .
  • 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 Contents Front axle system - 25 Powered front axle - 100 TECHNICAL DATA Four-Wheel Drive (4WD) axle General specification ............... 3 Torque .

  • Page 212: Four-Wheel Drive (4Wd) Axle

    Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - General specification Axle class Class 1 Unrestricted (static) axle capacity 2400.0 kg (5291.1 lb) Bevel gear pair - differential Pinion-ring gear ratio 9/38 = 1:4.2 Backlash between bevel gear pair 0.15 mm (0.006 in) - 0.20 mm (0.008 in) Bevel drive and differential 2.5 mm (0.0984 in) - 2.55 mm (0.1004 in) -...
  • Page 213 Front axle system - Powered front axle • Pivoting angle/oscillation (on either side) 11 ° • Center pivot and support end float 0.3 mm (0.0118 in) - 1.1 mm (0.0433 in) • Maximum wear clearance 2 mm (0.0787 in) 52.652 mm (2.0729 in) - 52.671 mm (2.0737 in) •...
  • Page 214 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Torque GNIL14TR04345GB Description Thread size Torque Lock ring, bevel pinion (C1) M35 x 1.5 294 N·m (217 lb ft) Bolt, differential case to axle casing (C2) M12 x 1.25 113 N·m (83 lb ft) Bolt, ring gear to differential case (C3) M12 x 1.25...
  • Page 215 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Special tools GNIL14TR04346HA 47866583_ 02/12/2015 25.1 [25.100] / 6...
  • Page 216 Front axle system - Powered front axle GNIL14TR04347HA 47866583_ 02/12/2015 25.1 [25.100] / 7...
  • Page 217 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Overview The tractor has a centrally pivoting front axle with the pivot and the drive shaft coaxial with the longitudinal axis of the tractor. The drive shaft has no universal joints. The differential has two planet pinions;...
  • Page 218 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Sectional view GNIL14TR04350FB Rear thrust washer 1.000 mm (0.039 in) 1.000 - 1.500 mm (0.039 - 0.059 in) Rear bushing Sleeve position shim Rear axle pivot support Axle pivot support bolt Retaining rings Front splined sleeve C10 Differential bearing cap bolt...
  • Page 219 Front axle system - Powered front axle GNIL14TR04351GB 0.500 - 1.000 mm (0.020 - 0.039 in) Ring gear Bevel pinion bearing shim Axle shaft with universal joint Bevel pinion position shim Side gear washers Bevel pinion bearing lock ring Differential pinion washers Differential pinion journal bolt Differential carrier bolt Ring gear bolt...
  • Page 220 Front axle system - Powered front axle GNIL14TR04352GB King pin bearing shim King pin bearing Wheel hub bearing shims Seal King pin bearing bolt Seal Steering knuckle bolt Axle shaft bushing Wheel hub bearing lock ring Spacer Final drive housing bolt Thrust washers Wheel hub bolt Planet wheel journals...
  • Page 221 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Remove WARNING 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 could result in death or serious injury.
  • Page 222 Front axle system - Powered front axle 4. Remove the snap ring (1) from the front and rear of the drive shaft. GNIL14TR04359AB 5. Remove the bolts (1) from the drive shaft support bear- ing. 6. Remove the drive shaft from the front axle input shaft and drop box output shaft by sliding the two couplers onto the drive shaft.
  • Page 223 Front axle system - Powered front axle 10. Remove the front wheels. GNIL14TR04363AA 11. Remove the front axle rear support retaining bolts (1). GNIL14TR04364AB 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.
  • Page 224 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Remove WARNING 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 could result in death or serious injury.
  • Page 225 Front axle system - Powered front axle 4. Remove the snap ring (1) from the front and rear of the drive shaft. GNIL14TR04359AB 5. Remove the bolts (1) from the drive shaft support bear- ing. 6. Remove the drive shaft from the front axle input shaft and drop box output shaft by sliding the two couplers onto the drive shaft.
  • Page 226 Front axle system - Powered front axle 10. Remove the front wheels. GNIL14TR04363AA 11. Remove the front axle rear support retaining bolts (1). GNIL14TR04364AB 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.
  • Page 227 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Install 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 mod- erate injury.
  • Page 228 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Disassemble WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear.
  • Page 229 Front axle system - Powered front axle 6. Remove the tie rod retaining nuts (1). GNIL14TR04371AB 7. Using a removal tool, remove the tie rod ends from their bores in the stub axle housing. GNIL14TR04372AA 8. Remove the snap ring from the bottom of the cylinder rod pivot pin (1) 9.
  • Page 230 Front axle system - Powered front axle 14. Remove the snap ring (1). 15. Remove the driving gear (2). GNIL14TR04375AB 16. Remove the staking (1) on the wheel hub bearing lock ring (2). GNIL14TR04377AB 17. Remove the wheel hub bearing lock ring using tool no 380000295 (1).
  • Page 231 Front axle system - Powered front axle 19. Remove the retaining bolts (1) of the lower pivot pin of the stub axle housing. 20. Remove the lower pivot pin and the relative adjust- ment shims. GNIL14TR04380AB 21. Remove the retaining bolts of the upper pivot pin. 22.
  • Page 232 Front axle system - Powered front axle 27. Remove the bolts fixing the bevel drive-differential support to the axle casing. 28. Screw in the M12 x 100 dowels, tool no 380002814 (1). 29. Remove the remaining bolts and separate the bevel drive-differential support from the axle casing.
  • Page 233 Front axle system - Powered front axle 36. Remove the nut using wrench, tool no 380000268 (1), while holding the bevel drive pinion shaft against rotation with wrench, tool no 380000257. GNIL14TR04388AB 37. Remove the splined shaft detent ball (1). GNIL14TR04389AB 38.
  • Page 234 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Inspect 1. Wash all parts in a suitable solvent and allow to air dry. 2. Inspect the 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.
  • Page 235 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Assemble 1. Reassemble the front axle. Adhere to the following instructions: • See Four-Wheel Drive (4WD) axle - Torque (25.100). • Install the rear bearing, the seal, the dust seal, the adjustment shims, the spacer and the bevel drive pinion shaft complete with front bearing.
  • Page 236 Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Adjust Adjustment of the ring gear bearings and checking the backlash between the pinion and ring gear Proceed as follows. 1. Install the differential assembly complete with ring gear and inner ring gear bearing rings in the bevel drive/ differential housing.

  • Page 237: Torque

    Front axle system - Powered front axle 4. Measure the backlash between pinion and ring gear, using a dial gauge (1) perpendicular to the outer edge of a tooth on the ring gear (2). 5. Repeat the measurement in two other positions 120° apart and compare the average of the three values (Gm) with the prescribed normal backlash specifica- tion of 0.18 mm (0.007 in) - 0.23 mm (0.009 in) aver-...
  • Page 238 Front axle system - Powered front axle 11. Gasket eliminator L ® 518 application diagram OCTITE for assembly of bevel drive unit and epicyclic final drive unit. GNIL14TR04394AB 47866583_ 02/12/2015 25.1 [25.100] / 29...

  • Page 239: Four-Wheel Drive (4Wd) Axle

    Front axle system - Powered front axle Four-Wheel Drive (4WD) axle - Toe in adjust When travelling forward in a straight path, the wheels of four-wheel drive tractors must be parallel to the lon- gitudinal axis of the tractor, alternatively a slight toe-in of the front wheels is permissible up to a maximum of 6 mm (0.24 in) as measured at the edges of the wheel rims.
  • Page 240 Index Front axle system - 25 Powered front axle - 100 Four-Wheel Drive (4WD) axle - Adjust ........... . Four-Wheel Drive (4WD) axle - Assemble .
  • 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: Four-Wheel Drive (4Wd) Axle

    Front axle system - Front bevel gear set and differential Differential - Adjust - 4WD Front axle Prior operation: Four-Wheel Drive (4WD) axle - Disassemble (25.100). End play adjustment In case of differential assembly overhaul it is necessary to adjust the backlash between the teeth of the planet pinions and side gears.
  • Page 245 Front axle system - Front bevel gear set and differential 7. Install shims, (1), as near as possible to the calculated value. Use a dial gauge and following the procedure described above, check that the end float of the left and right-hand side gears is approximately 0.25 mm (0.010 in).
  • Page 246 Index Front axle system - 25 Front bevel gear set and differential - 102 Differential - Adjust - 4WD Front axle ........... . . 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: Remove

    Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 SERVICE Steering knuckle and king pin Remove ................. . 3 Adjust (Stub Axle) .
  • Page 250 Front axle system - Final drive hub, steering knuckles, and shafts Steering knuckle and king pin - Remove In the event that the steering knuckle pins prove difficult to remove, proceed as follows. 1. Remove the grease nipples and the steering knuckle pin retaining bolts.
  • Page 251 Front axle system - Final drive hub, steering knuckles, and shafts Steering knuckle and king pin - Adjust (Stub Axle) WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 252 Front axle system - Final drive hub, steering knuckles, and shafts 7. Partially unscrew the bolts of the lower cover, insert the shims and tighten the bolts to a torque value of 64 N·m (47 lb ft). 8. After having rotated the casing a few times to allow the components to bed down, 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...
  • Page 253 Front axle system - Final drive hub, steering knuckles, and shafts Wheel hub - Adjust (4WD) – Front Axle 1. Proceed as follows: • Install wheel hub and fixed gear unit onto the steer- ing knuckle. • Using a torque wrench and lock ring wrench, tool number 380000295, progressively tighten the lock ring to 147 - 196 N·m (108 - 145 lb ft).
  • Page 254 Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 Steering knuckle and king pin - Adjust (Stub Axle) ......... . Steering knuckle and king pin - Remove .
  • 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 –...
  • Page 258 Front axle system - Final drives Final drive driving pinion - Preload – (4WD) Front Axle WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 259 Front axle system - Final drives If necessary, round the value thus obtained up to the nearest 0.05 mm (0.002 in). Pinion positioning shim (1) is located between pinion 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.
  • Page 260 Front axle system - Final drives Final drive driving pinion - Adjust – (4WD) Front Axle Determining the thickness of the drive pinion position adjustment shim Proceed as follows. 1. Install tool number 380000249 (1) in the bevel drive- differential housing complete with outer bearing rings, ring gear bearings adjustment ring, ring gear bearings adjustment shim, circlip and differential support caps.
  • Page 261 Front axle system - Final drives Available shim sizes 2.6 mm (0.102 in) 2.9 mm (0.114 in) 2.65 mm (0.104 in) 2.95 mm (0.116 in) 2.7 mm (0.106 in) 8. Install the O-ring seal (1) on the drive pinion shaft. 9.
  • Page 262 Index Front axle system - 25 Final drives - 310 Final drive driving pinion - Adjust – (4WD) Front Axle ........Final drive driving pinion - Preload –...
  • 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 Contents Front axle system - 25 Non-powered front axle - 400 TECHNICAL DATA Non-powered front axle General specification ............... 3 Torque .
  • Page 266 Front axle system - Non-powered front axle Non-powered front axle - General specification Centrally pivoted U-type centre beam without telescopic Type outer section 2 ° corresponding to approx. 15.00 mm (0.59 in) with Wheel camber 406.40 mm (16.00 in) rims 0.000 - 5.000 mm (0.000 - 0.197 in) Wheel toe-in Swivel pin assembly...
  • Page 267 Front axle system - Non-powered front axle GNIL14TR04431GB Non-powered front axle - 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 ®...
  • Page 268 Front axle system - Non-powered front axle Non-powered front axle - Overview The adjustable front axle is composed of a reversed U-type centre beam with telescopic sections at each end. A number of holes at 50.00 mm (2.00 in) intervals are provided in the telescopic sections for track width adjustment purpose.
  • Page 269 Front axle system - Non-powered front axle Non-powered front axle - Sectional view GNIL14TR04432FB Front axle support Grease fitting Thrust washers Axle centre beam Axle pivot pin Axle pivot pin bushings Front axle carrier 47866583_ 02/12/2015 25.5 [25.400] / 6...
  • Page 270 Front axle system - Non-powered front axle GNIL14TR04433GB Stub assembly Dust cover 11. Grease nipple 12. Bearing Oil seal Bush upper 13. Thrust washer Bush lower 14. Castle nut 15. Split pin Thrust washer Seal 16. Dust cover Dust cover 17.
  • Page 271 Front axle system - Non-powered front axle Non-powered front axle - Remove 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.
  • Page 272 Front axle system - Non-powered front axle 8. Remove the axle pivot pin locking bolt (1). GNIL14TR04437AB 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.
  • Page 273 Front axle system - Non-powered front axle Non-powered front axle - Install Reinstall the front axle assembly to carrier observing the following: 1. Reassembly follows disassembly procedure in reverse, refer to Non-powered front axle - Remove (25.400). CAUTION Pinch hazard! Always use suitable tools to align mating parts.
  • Page 274 Front axle system - Non-powered front axle Front axle - Remove – Spindle Assembly WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 275 Front axle system - Non-powered front axle 7. Remove the axle outer section (1) attaching bolts. GNIL14TR04452AB 8. Remove the axle outer section (1). GNIL14TR04453AB 47866583_ 02/12/2015 25.5 [25.400] / 12...
  • Page 276 Front axle system - Non-powered front axle Front axle - Overhaul – Spindle Assembly 1. Fix the axle outer section in a vice and remove the upper seal using suitable tool. GNIL14TR04454AA 2. Remove the bottom seal using suitable tool and recover thrust washer.
  • Page 277 Front axle system - Non-powered front axle Front axle - Install – Spindle 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.
  • Page 278 Front axle system - Non-powered front axle Axle wheel hub - Remove WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 279 Front axle system - Non-powered front axle 6. Using the socket spanner loosen the wheel hub bear- ing. Adjust castle nut. GNIL14TR04442AA 7. Remove wheel hub (2) and recover bearing (1) and (3). GNIL14TR04443AB 8. Remove seal (1) and nyloc ring (2) using suitable tool. GNIL14TR04444AB 47866583_ 02/12/2015 25.5 [25.400] / 16...
  • Page 280 Front axle system - Non-powered front axle Axle wheel hub - Install 1. Replace faulty seals and worn bearing using suitable pullers and drifts. 2. Fill the wheel hub with specified grease. 3. Re-assemble the wheel hub (2) complete with the bear- ings (1) and (3).
  • Page 281 Front axle system - Non-powered front axle Non-powered front axle - Troubleshooting Problem Possible Cause Correction Premature tire wear Wrong inflation pressure Inflate 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...
  • Page 282 Index Front axle system - 25 Non-powered front axle - 400 Axle wheel hub - Install ..............Axle wheel hub - Remove .
  • Page 283 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 284 SERVICE MANUAL Rear axle system Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 285 Contents Rear axle system - 27 [27.100] Powered rear axle..............27.1 [27.106] Rear bevel gear set and differential .
  • 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 Rear axle system - Powered rear axle Powered rear axle - Overview The rear axle assembly transfers drive from the transmission to the planet drive through a bevel pinion and crown wheel coupling. The bevel gears are spiral type and are supported by tapered roller bearings. The differential is fitted with four planetary and two side gears and mechanical lock.
  • Page 289 Index Rear axle system - 27 Powered rear axle - 100 Powered rear axle - Overview ............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 Contents Rear axle system - 27 Rear bevel gear set and differential - 106 TECHNICAL DATA Rear bevel gear set and differential General specification ............... 3 Torque .
  • Page 292 Rear axle system - Rear bevel gear set and differential Rear bevel gear set and differential - General specification Pinion to crown wheel and differential Pinion and crown wheel ratio Pinion to crown wheel backlash 0.180 mm (0.007 in) - 0.230 mm (0.009 in) Differential 4 pin Differential lock control type...
  • Page 293 Rear axle system - Rear bevel gear set and differential GNIL14TR04239GB Rear bevel gear set and differential - Special tools Tool description Tool number Differential plate check nut tightening tool 9971349 Installer oil seal wheel side (heavy duty) 84261386 Set screw socket 6.000 mm (0.236 in) 84261394 Yoke and spreader 291051 and 291052...
  • Page 294 Rear axle system - Rear bevel gear set and differential GNIL14TR04240GB 47866583_ 02/12/2015 27.2 [27.106] / 5...
  • Page 295 Rear axle system - Rear bevel gear set and differential Rear bevel gear set and differential - Sectional view Crown wheel and differential assembly GNIL14TR04241GB Crown wheel Power Take-Off (PTO) shaft Pinion shaft Differential assembly Brake Input shaft Power Take-Off (PTO) input shaft 47866583_ 02/12/2015 27.2 [27.106] / 6...
  • Page 296 Rear axle system - Rear bevel gear set and differential Rear bevel gear set and differential - Remove Crown wheel and differential housing To remove the crown wheel and differential housing, final drive housing, brake assembly and Power Take-Off (PTO) assembly has to be removed. Remove the rear axle housing as follows: 1.
  • Page 297 Rear axle system - Rear bevel gear set and differential 4. Loosen the bolts (1), detach electrical connection and remove operator seat from the hydraulic housing. GNIL14TR04246AB 5. Disconnect hydraulic lines (1) on the hydraulic lift body. GNIL14TR00798AA 6. Remove three point linkages from the tractor. GNIL14TR00562AA 7.
  • Page 298 Rear axle system - Rear bevel gear set and differential 8. Place the wedges at front and back on both sides of front tires. 9. Jack up rear axle of the tractor and place two suitable stands under transmission housing to raise the wheels off the ground.
  • Page 299 Rear axle system - Rear bevel gear set and differential 13. Loosen the bolts (1) and remove ROPS. GNIL14TR04251AA 14. Wrap suitable chain or nylon rope on the final drive housing (1) and connect it to a hoist. Loosen attaching bolts and remove the entire final drive.
  • Page 300 Rear axle system - Rear bevel gear set and differential 19. Remove PTO RPM sensor cable. Loosen the rear Power 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. Rear mechanical control - Remove (31.101).

  • Page 301: Install

    Rear axle system - Rear bevel gear set and differential Rear bevel gear set and differential - Install 1. Re-install the differential housing observing the follow- ing. • Re-assembly follows the disassembly procedure in reverse. See Rear bevel gear set and differential - Install (27.106).
  • Page 302 Rear axle system - Rear bevel gear set and differential GNIL14TR04259GA Pattern for application of sealant during installation of Power Take-Off (PTO) cover, final drive housing and mechanical 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.
  • Page 303 Rear axle system - Rear bevel gear set and differential Differential - Disassemble WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 304 Rear axle system - Rear bevel gear set and differential 4. Lift the cover (1) as shown to get access to differential gears. GNIL14TR04263AB 5. Remove the locking pin (1) locking the differential gear pivot pin. GNIL14TR04264AB 6. Remove the pivot pin (1) and withdraw the side gears from the differential housing along with trust washer.
  • Page 305 Rear axle system - Rear bevel gear set and differential 7. Using suitable puller special tool number 291051 and 291052 remove the bearings from both the sides. GNIL14TR04267AA 8. Remove the differential lock clutch from the housing. GNIL14TR04268AB 47866583_ 02/12/2015 27.2 [27.106] / 16...
  • Page 306 Rear 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 Rear axle system - Rear bevel gear set and differential Differential - Assemble 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 Re-install all the components of the differential assem- bly observing the following.
  • Page 308 Rear axle system - Rear bevel gear set and differential Differential - Backlash Differential pinion and side gear backlash adjustment Fit the two side gears (15) in the differential carrier with- out the shims (12). Install differential pinions (13) complete with thrust washer (14) and journal (3) and tighten bolts (1) a few turns to prevent journal work out.
  • Page 309 Rear axle system - Rear bevel gear set and differential 2. Tighten left-hand side ring nut (1) using special tool number 9971349 until minimum backlash between the bevel teeth is 1.000 mm (0.039 in). GNIL14TR04272AB 3. Measure the backlash using dial gauge and magnetic stand as shown in figure.
  • Page 310 Rear axle system - Rear bevel gear set and differential Bevel pinion - Remove WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 311 Rear axle system - Rear bevel gear set and differential 4. Open the lock of pinion locking check nut with the help of screw driver. GNIL14TR04072AA 5. Fit pinion locking tool special tool (1) number 84261392. GNIL14TR04073AB 6. Remove the pinion shaft lock nut using special tool number 84261389.
  • Page 312 Rear axle system - Rear bevel gear set and differential 8. Remove the circlip lock of the Gama Basasa bearing to remove bearing cone (1) from the housing. GNIL14TR04076AB 9. Remove bearing from the pinion shaft using special tool number 291051 and 291052. GNIL14TR04077AB 47866583_ 02/12/2015 27.2 [27.106] / 23...
  • Page 313 Rear axle system - Rear bevel gear set and differential Bevel pinion - Install 1. Install the bearing on pinion. GNIL14TR04078AB 2. Fit the outer cone of Gama Bassa bearing and fit circlip lock. GNIL14TR04079AA 3. Fit pinion shaft along with hub range, sliding sleeve, bush and low gear as shown.
  • Page 314 Rear axle system - Rear bevel gear set and differential Rear bevel gear set and differential - Troubleshooting Problem Possible Cause Correction Noisy rear axle when the 1. Pinion and/or ring gear bearing wrong Remove rear axle housing and adjust pin- tractor is moving and ion and ring gear bearings correctly adjustment...
  • Page 315 Index Rear axle system - 27 Rear bevel gear set and differential - 106 Bevel pinion - Install ..............Bevel pinion - Remove .
  • 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 Contents Rear axle system - 27 Planetary and final drives - 120 TECHNICAL DATA Planetary and final drives General specification ............... 3 FUNCTIONAL DATA Final drive housing Sectional view .
  • Page 318 Rear axle system - Planetary and final drives Planetary and final drives - General specification Type Epicyclic 6.550 mm (0.258 in) Reduction ratio 47866583_ 02/12/2015 27.3 [27.120] / 3...
  • Page 319 Rear axle system - Planetary and final drives Final drive housing - Sectional view GNIL14TR04242FB Final drive Trumpet housing Planet gear Rear wheel shaft 47866583_ 02/12/2015 27.3 [27.120] / 4...
  • Page 320 Rear axle system - Planetary and final drives Final drive housing - Disassemble WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 321 Rear axle system - Planetary and final drives 4. Remove the check chain and lower link of the three point linkage. GNIL14TR00864AA 5. Remove the ROPS (Roll Over Protective Structure). NOTE: Use a suitable hoist. GNIL14TR00865AA 6. 1. Wrap chain around final drive housing and loosen bolts (1).
  • Page 322 Rear axle system - Planetary and final drives 8. Remove the linkage (1). GNIL14TR00792AA 9. Remove the nut and spring. Remove the circlip. GNIL14TR00791AA 10. Remove brake disc (1) and shaft (2). GNIL14TR04277AB 11. Remove the brake actuator assembly (1). GNIL14TR04278AB 47866583_ 02/12/2015 27.3 [27.120] / 7...
  • Page 323 Rear axle system - Planetary and final drives 12. Remove second brake disc. GNIL14TR00779AA 13. Remove intermediate plate and third brake disc. GNIL14TR00780AA 14. Remove dual brake support (1) as shown. GNIL14TR04279AB 15. Remove the set screw (1) holding the cover for road wheel shaft.
  • Page 324 Rear axle system - Planetary and final drives 16. Remove spacers (1) planet final drive. GNIL14TR04281AB 17. Remove all three planet gears along with needle bear- ings. GNIL14TR04282AB 18. Remove the circlip lock (1) of planet carrier sub as- sembly. GNIL14TR04283AB 19.
  • Page 325 Rear axle system - Planetary and final drives 20. Remove planet carrier sub assembly (1). GNIL14TR04285AB 21. Check planet gear spacers and needle bearings for damage, replace if found worn out. GNIL14TR04286AA 22. Hammer the wheel axle shaft out of the final drive housing.
  • Page 326 Rear axle system - Planetary and final drives 24. Loosen the three bolts of mud protection cover from the final drive housing. GNIL14TR04289AB 25. Retrieve oil seal from the housing. GNIL14TR04290AA 26. Retrieve the taper roller bearing, external spacer seal and oil seal from the trumpet.
  • Page 327 Rear axle system - Planetary and final drives Final drive housing - Assemble Reinstall wheel and axle shaft in final drive housing observing the following: • Re assembling follows the removal procedure. See Final drive housing - Disassemble (27.120). • Refer to figure for correct orientation of the shafts bearings sleeves and seals.
  • Page 328 Rear axle system - Planetary and final drives Final drive housing - Troubleshooting Problem Possible Cause Correction Noisy final drives when 1. Wheel axle shaft bearing badly adjusted Remove final drive case and adjust bear- the tractor is moving and ings also with transmission in neutral...
  • Page 329 Index Rear axle system - 27 Planetary and final drives - 120 Final drive housing - Assemble ............Final drive housing - Disassemble .
  • Page 330 47866583_ 02/12/2015 27.3 [27.120] / 15...
  • Page 331 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 332 SERVICE MANUAL Power Take-Off (PTO) Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 333 Contents Power Take-Off (PTO) - 31 [31.101] Rear mechanical control ............. 31.1 [31.110] One-speed rear Power Take-Off (PTO) .
  • 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 Contents Power Take-Off (PTO) - 31 Rear mechanical control - 101 TECHNICAL DATA Rear mechanical control General specification ............... 3 Torque .
  • Page 336 Power Take-Off (PTO) - Rear mechanical control Rear mechanical control - General specification Type Single Speed 540 rpm PTO is provided in base model. Double Speed 540/540E rpm PTO with Ground Speed is provided as an option. Engagement and control Through mechanical clutch Rotation (looking from tractor rear end) Clock wise...
  • Page 337 Power Take-Off (PTO) - Rear mechanical control GNIL14TR00831GA Rear mechanical control - Sealing Operation description Sealant specification Power Take-Off (PTO) rear cover (S1) ® 518 OCTITE Hydraulic to transmission housing (S2) ® 518 OCTITE 47866583_ 02/12/2015 31.1 [31.101] / 4...
  • Page 338 Power Take-Off (PTO) - Rear mechanical control GNIL14TR04296FB Rear mechanical control - Special tools Operation description Tools specification 84261381 Power Take-Off (PTO) rear cover seal installer Yoke and spreader 291051 and 291052 47866583_ 02/12/2015 31.1 [31.101] / 5...
  • Page 339 Power Take-Off (PTO) - Rear mechanical control Rear mechanical control - Sectional view GNIL14TR00826FA Transmission input shaft Power Take-Off (PTO) engaging sleeve Power Take-Off (PTO) input shaft Power Take-Off (PTO) shaft Reduction gear 47866583_ 02/12/2015 31.1 [31.101] / 6...
  • Page 340 Power Take-Off (PTO) - Rear mechanical control Rear mechanical control - Remove PTO shaft assembly 1. Remove hydraulic lift assembly by following the proce- dures given in Main lift system - Remove (35.100). 2. Disconnect the PTO RPM sensor electrical connection. Loosen the bolts (1) and remove the PTO RPM sensor.
  • Page 341 Power Take-Off (PTO) - Rear mechanical control 5. Push out roll pin (1) and remove main PTO lever (2) from the shaft. GNIL14TR04303AB 6. Loosen set screw (1) and remove plate. GNIL14TR04304AB 7. Remove roll pin holding differential lock fork (1) and PTO coupler fork.
  • Page 342 Power Take-Off (PTO) - Rear mechanical control 9. Push out the differential lock shaft (1) and PTO lever shaft. GNIL14TR04308AB 10. Remove PTO fork (1). GNIL14TR04309AB 11. Remove differential lock pedal fork (1). GNIL14TR04310AB PTO input shaft cover 12. Loosen the bolts and remove the PTO input shaft cover.
  • Page 343 Power Take-Off (PTO) - Rear mechanical control 13. Loosen the bolt from the inner side of the cover plate. GNIL14TR00738AA 14. Retrieve the inner plate and the spring from the cover. GNIL14TR00739AA 47866583_ 02/12/2015 31.1 [31.101] / 10...
  • Page 344 Power Take-Off (PTO) - Rear mechanical 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 Index Power Take-Off (PTO) - 31 Rear mechanical control - 101 Rear mechanical control - General specification ..........Rear mechanical control - Install .
  • 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: Disassemble

    Contents Power 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 .
  • Page 348 Power Take-Off (PTO) - One-speed rear Power Take-Off (PTO) One-speed rear Power Take-Off (PTO) - Overview The Power Take-Off (PTO) transfers engine power di- rectly to mounted, semi-mounted or trailed equipment via a splined shaft at the rear of the tractor. The system utilizes the standard 6 -splines shaft designed to operator at 540 RPM, the speed at which most Power Take-Off (PTO) driven equipment is designed to run.
  • Page 349 Power Take-Off (PTO) - One-speed rear Power Take-Off (PTO) One-speed rear Power Take-Off (PTO) - Disassemble 1. Remove the hydraulic lift assembly, PTO external con- trol and PTO cover. See Rear mechanical control - Remove (31.101). 2. Remove the PTO input shaft cover. Remove the PTO coupler (1).
  • Page 350 Power Take-Off (PTO) - One-speed rear 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 47866583_ 02/12/2015 31.2 [31.110] / 5...
  • Page 351 Index Power Take-Off (PTO) - 31 One-speed rear Power Take-Off (PTO) - 110 One-speed rear Power Take-Off (PTO) - Assemble ......... One-speed rear Power Take-Off (PTO) - Disassemble .
  • 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 Contents Power Take-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 .
  • Page 354 Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO) Two-speed rear Power Take-Off (PTO) - Overview The Power Take-Off (PTO) transfers engine power di- rectly to mounted, semi-mounted or trailed equipment via a splined shaft at the rear of the tractor. The system utilizes the standard 6 -splines shaft designed to operator at 540 RPM, the speed at which most Power Take-Off (PTO) driven equipment is designed to run.
  • Page 355 Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO) Two-speed rear Power Take-Off (PTO) - Disassemble 1. Remove circlip lock (1) from the outer hollow Power Take-Off (PTO) shaft and remove coupling gear. GNIL14TR00745AA 2. Remove the circlip lock (1), needle roller bearing. Take out the hollow Power Take-Off (PTO) shaft.
  • Page 356 Power Take-Off (PTO) - 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 47866583_ 02/12/2015 31.3 [31.114] / 5...
  • Page 357 Power Take-Off (PTO) - Two-speed rear 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 47866583_ 02/12/2015 31.3 [31.114] / 6...
  • Page 358 Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO) Two-speed rear Power Take-Off (PTO) - Assemble Power Take-Off (PTO) shaft assembly Re-install Power Take-Off (PTO) shaft assembly in dif- ferential housing observing the following: • Re-assembling follows the disassembly procedure in reverse.
  • Page 359 Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO) GNIL14TR04320GA 47866583_ 02/12/2015 31.3 [31.114] / 8...
  • Page 360 Index Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114 Two-speed rear Power Take-Off (PTO) - Assemble ......... Two-speed rear Power Take-Off (PTO) - Disassemble .
  • Page 361 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 362 SERVICE MANUAL Brakes and controls Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 363 Contents Brakes and controls - 33 [33.120] Mechanical service brakes ............33.1 47866583_ 02/12/2015...
  • 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 Contents Brakes and controls - 33 Mechanical service brakes - 120 TECHNICAL DATA Mechanical service brakes General specification ............... 3 Special tools .
  • Page 366 Brakes and controls - Mechanical service brakes Mechanical service brakes - General specification Type Oil immersed disc brakes acting on differential axle shaft Control Mechanical, independent pedal control Service brake Parking brake Mechanical, hand lever pull type Number of discs per side 3 each side Brake oil specification APGSAE 20W30...
  • Page 367 Brakes and controls - Mechanical service brakes GNIL14TR00832GA Mechanical service brakes - Sealing Operation description Sealant specification Buckle up of rear axle housing to differential housing (S1) ® 518™ OCTITE 47866583_ 02/12/2015 33.1 [33.120] / 4...
  • Page 368 Brakes and controls - Mechanical service brakes GNIL14TR04327FB 47866583_ 02/12/2015 33.1 [33.120] / 5...
  • Page 369 Brakes and controls - Mechanical service brakes Mechanical service brakes - Exploded view GNIL14TR00841GB 47866583_ 02/12/2015 33.1 [33.120] / 6...
  • Page 370 Brakes and controls - Mechanical service brakes Mechanical service brakes - Overview See Mechanical service brakes - Exploded view (33.120). Oil immersed brakes used, has two brake discs (1) both externally lined with friction material are supported by brake actuator (2) mounted on brake housing (8). An actuating assembly is mounted between the brake discs (1), which consists of two discs (3) separated by steel balls (4) but connected by short springs (5).
  • Page 371 Brakes and controls - Mechanical service brakes Mechanical service brakes - Sectional view GNIL14TR00833FA (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 Brakes and controls - Mechanical service brakes Mechanical service brakes - Remove To remove brake assembly, rear axle assembly has to be removed from the transmission. 1. Remove the pin (1) and disconnect the brake linkage. GNIL14TR00789AA 2. Wrap chain around final drive housing and loosen bolts (1).
  • Page 373 Brakes and controls - Mechanical service brakes 5. Remove the nut and spring. Remove the circlip. GNIL14TR00791AA 6. Remove brake disc (1) and shaft (2). GNIL14TR04277AB 7. Remove the brake actuator assembly (1). GNIL14TR04278AB 8. Remove second brake disc. GNIL14TR00779AA 47866583_ 02/12/2015 33.1 [33.120] / 10...
  • Page 374 Brakes and controls - Mechanical service brakes 9. Remove intermediate plate and third brake disc. GNIL14TR00780AA 10. Remove dual brake support (1) as shown. GNIL14TR04279AB 47866583_ 02/12/2015 33.1 [33.120] / 11...
  • Page 375 Brakes and controls - Mechanical service brakes Mechanical service brakes - 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’...
  • Page 376 Brakes and controls - Mechanical service brakes Mechanical service brakes - Install NOTE: Always use suitable tools to align holes. Do not use hand or fingers. 1. Reinstall the brake assembly and rear axle housing to the differential housing taking the following into consid- eration.
  • Page 377 Brakes and controls - Mechanical service brakes GNIL14TR04342FA 47866583_ 02/12/2015 33.1 [33.120] / 14...
  • Page 378 Brakes and controls - Mechanical service brakes Brake control pedals and shafts - Remove 1. Remove circlip (1). Unlock the clip (2) and remove pin (3) from the left-hand and right-hand side brake link- ages. GNIL14TR00766AA 2. Remove the brake pedal springs. Remove the clutch pedal springs.
  • Page 379 Brakes and controls - Mechanical service brakes Parking brake 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 7. Loosen the bolt (1) and remove hand brake pawl (2). GNIL14TR04334AB 47866583_ 02/12/2015 33.1 [33.120] / 16...
  • Page 380 Brakes and controls - Mechanical service brakes Brake control pedals and shafts - Adjust 1. Measure free play of the brake pedals as shown in 1 and should be 50.00 - 55.00 mm (1.97 - 2.17 in). With the brake pedals locked together, the tractor should stop in a straight line when brakes are applied.
  • Page 381 Brakes and controls - Mechanical service brakes Mechanical service brakes - Troubleshooting Problem Possible Cause Correction Brake actuate only when Incorrect Pedal adjustment Check and adjust pedal is depressed fully Tractor pulls to one side Brakes not equally adjusted Adjust when brakes applied Wrong tire pressure Inflate tires to correct pressure...
  • Page 382 Index Brakes and controls - 33 Mechanical service brakes - 120 Brake control pedals and shafts - Adjust ..........Brake control pedals and shafts - Remove .
  • Page 383 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 384 SERVICE MANUAL Hydraulic systems Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 385 Contents Hydraulic systems - 35 [35.000] Hydraulic systems..............35.1 [35.100] Main lift system.

  • Page 386: Hydraulic Systems

    Hydraulic systems - 35 Hydraulic systems - 000 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 35.1 [35.000] / 1...
  • Page 387 Contents Hydraulic systems - 35 Hydraulic systems - 000 FUNCTIONAL DATA Hydraulic systems Overview ................. . 3 Hydraulic schema .
  • Page 388 Hydraulic systems - Hydraulic systems Hydraulic systems - Overview The hydraulic system on the tractor is for mechanical lift assembly to raise and lower the lift arms and thus the three point linkage. The high pressure hydraulic circuit is an open centre load sensing type. The hydraulic lift is connected to the hydraulic pump.
  • Page 389 Hydraulic systems - Hydraulic systems Hydraulic systems - Hydraulic schema GNIL14TR00817GA 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 Hydraulic circuit diagram 47866583_ 02/12/2015 35.1 [35.000] / 5...
  • Page 391 Hydraulic systems - Hydraulic systems Hydraulic systems - Component identification Pump Open centre hydraulic pump assembly is of high pressure gear pump (1). GNIL14TR00519AA Filter Full-flow spin on type filter (1) mounted on right side of the engine on suction pump. GNIL14TR00519AA Mechanical hydraulic lift assembly Mounted on top of transmission housing comprising of following components:...
  • Page 392 Hydraulic systems - Hydraulic systems • Distributor (3) • Response control valve (4) GNIL14TR00804AA • Draft sensing unit (8) • Lift arms (9) • Internal linkages and cylinder assembly GNIL14TR04568AB 47866583_ 02/12/2015 35.1 [35.000] / 7...
  • Page 393 Hydraulic systems - Hydraulic systems Hydraulic systems - Troubleshooting Problem Possible Cause Correction Lift arms lift jerky Hydraulic oil level low Add hydraulic oil to correct level Suction Filter is clogged Replace oil filter Pump has an air suction leak Check all inlet pipe connections Lift arms do not lift Inner control valve spool not shifting to...
  • Page 394 Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Component identification ..........Hydraulic systems - Hydraulic schema .
  • Page 395 47866583_ 02/12/2015 35.1 [35.000] / 10...

  • Page 396: [35.100] Main Lift System

    Hydraulic systems - 35 Main lift system - 100 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 35.2 [35.100] / 1...
  • Page 397 Contents Hydraulic systems - 35 Main lift system - 100 TECHNICAL DATA Main lift system General specification ............... 3 Torque .
  • Page 398 Hydraulic systems - Main lift system Main lift system - General specification With separate position or draft control, Mixed position/draft control Type plus draft sensitivity and float control Control Through two independent levers external knob on control valve Through external knob on control valve Response/drop rate adjustment Single-acting cylinder 85.0 mm (3.3 in) x 88.0 mm (3.5 in) for 1100.0 kg (2425.1 lb)
  • Page 399 Hydraulic systems - Main lift system GNIL14TR00819GA Main lift system - Sealing Operation description Sealant specification Lift housing to transmission housing (S1) ® 518™ OCTITE 47866583_ 02/12/2015 35.2 [35.100] / 4...
  • Page 400 Hydraulic systems - Main lift system GNIL14TR04583FB 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 Hydraulic systems - Main lift system Main lift system - Dynamic description Control levers A) Position control B) Draft control C) Combined operation for position and draft control The above operations may be chosen in consideration of the work to be carried out, the implement type and the soil superficial hardness.
  • Page 402 Hydraulic systems - Main lift system Combined operation for position and draft control In case of workings carried out under draft control on not-homogeneous soils, during which excessive implement penetration may occur, it is convenient to use the combined position and draft control. Have the implement penetrated into the ground and search for the desired working depth in the way described for the draft control.
  • Page 403 Hydraulic systems - Main lift system By positioning the draft control lever (2) against the backstop. The roller (11) which slides on the flywheel (7) of draft cam (12), will be moved away completely. In this way the draft levers will not in anyway interfere with the operation of the position control. The arms are raised by moving the position control lever (1) upward, and the leverage system will act in the following way.
  • Page 404 Hydraulic systems - Main lift system (9) that is pushed by the spring of shaft (21) which in turn will position itself for the discharge position (S). In this way the position levers will not interfere with the functioning of the draft control levers. By positioning the draft control lever (2) against backstop.
  • Page 405 Hydraulic systems - Main lift system Combined functioning of position and draft control GNIL14TR04602FB To utilise the lifting device in this condition it is necessary to observe the following instructions: • Move the position control lever (1) upwards with respect to the backstop (E) until the maximum working depth has been attained.
  • Page 406 Hydraulic systems - Main lift system Main lift system - Remove WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 407 Hydraulic systems - Main lift system 4. Loosen the bolts securing hydraulic 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.
  • Page 408 Hydraulic systems - Main lift system Main lift system - Install 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 Refit the hydraulic lift on the transmission housing as follows.
  • Page 409 Hydraulic systems - Main lift system Main lift system - Disassemble WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 410 Hydraulic systems - Main lift system Draft sensing unit - Disassembly 6. Loosen set screws (1). GNIL14TR04621AB 7. Disassemble 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.
  • Page 411 Hydraulic systems - Main lift system 10. Remove the cylinder (1) from hydraulic lift housing. GNIL14TR04625AB NOTE: Retrieve the seal (1) from head of cylinder. GNIL14TR04626AB 11. Remove the piston (1) from the cylinder by pushing with a suitable aluminium rod from the front side. GNIL14TR04627AB 12.
  • Page 412 Hydraulic systems - Main lift system 13. Remove linkage (1). GNIL14TR04633AB 14. Remove the lock (1) from the compensator pin. GNIL14TR04632AB 15. Unscrew the compensator pin until face of the pin comes out of the compensator. GNIL14TR04634AB 16. Remove linkages as shown in figure. GNIL14TR04635AB 47866583_ 02/12/2015 35.2 [35.100] / 17...
  • Page 413 Hydraulic systems - Main lift system 17. Remove link (1). GNIL14TR04636AB 18. Unscrew locking screw (1) and remove position con- trol cam (2) and bracket (3). GNIL14TR04637AB 19. Remove dowel pin (1). GNIL14TR04638AB 20. Remove cam (1). GNIL14TR04639AB 47866583_ 02/12/2015 35.2 [35.100] / 18...
  • Page 414 Hydraulic systems - Main lift system 21. Remove lock (1) and disassemble link (2). GNIL14TR04641AB 22. Unscrew locking screw (1) and disassemble lever (2) along with link (3). GNIL14TR04641AB Lift arm shaft - removal 23. Remove lift assembly from the tractor and fix it on a rotary stand.
  • Page 415 Hydraulic systems - Main lift system 25. Remove the lift arm from the shaft. NOTE: Before removing lift arm punch a mark (1) on both lift arm and shaft to facilitate the assembly in original posi- tion. GNIL14TR04644AB 26. Repeat the same for the other side lift arm. GNIL14TR04645AB 27.
  • Page 416 Hydraulic systems - Main lift system Main lift system - Assemble Draft sensing unit Assemble and reinstall sensing unit on hydraulic hous- ing observing the following: 1. Assembly and reinstallation follows the removal proce- dure is reverse from step 7 to step 1. 2.
  • Page 417 Hydraulic systems - Main lift system Main lift system - Adjust In case of complete disassembly of the lift it is neces- sary to make the following adjustments: A. Control valve sensitivity setting B. Position control lever setting C. Draft control lever setting D.
  • Page 418 Hydraulic systems - Main lift system GNIL14TR04652FB B. Draft control lever setting With reference to 2. The adjustment of the draft control lever must be carried out to have a correct synchronisation between this lever and the stroke (positive and negative) of the top link bracket in order to make full use of the reaction spring.
  • Page 419 Hydraulic systems - Main lift system GNIL14TR04653FB C. Reaction spring setting With reference to figure 3. For a correct functioning of the rockshaft the top link bracket, when it is not working, must not have an axial play in the positive (+) and negative (-). After having carried out a correct assembly, the spring holder (2) must rest against the rockshaft housing (1), while the spring holder cover (4) must rest against the...
  • Page 420 Hydraulic systems - Main lift system GNIL14TR04654FB D. Internal push rod setting With reference to figure 4. If the rockshaft is disassembled and if the regulator (R) must be changed it is advisable to control the measure- ment “X” (~10,5) in order to re-assemble the push rod in the same position.
  • Page 421 Hydraulic systems - Main lift system GNIL14TR04655FB 47866583_ 02/12/2015 35.2 [35.100] / 26...
  • Page 422 Hydraulic systems - Main lift system Main lift system - Inspect GNIL14TR04650FB The pre selector (P) is used to connect the auxiliary port-thread M18 x 1.5 and send the oil to a single acting cylinder-for example a wagon dump-and moving it with the draft lever (2).
  • Page 423 Hydraulic systems - Main lift system 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 Hydraulic systems - Main lift system Main lift system - Troubleshooting Problem Possible Cause Correction The Rockshaft lifts jerkily Insufficient oil level in the tank Top up the level Pump inlet filter clogged Clean or replace the filter Infiltration of air into the pump inlet pipe Check the inlet pipe and any coupling and gasket Rockshaft does not...
  • Page 425 Index Hydraulic systems - 35 Main lift system - 100 Main lift system - Adjust ..............Main lift system - Assemble .

  • Page 426: [35.104] Fixed Displacement Pump

    Hydraulic systems - 35 Fixed displacement pump - 104 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 35.3 [35.104] / 1...
  • Page 427 Contents Hydraulic systems - 35 Fixed displacement pump - 104 TECHNICAL DATA Fixed displacement pump General specification ............... 3 SERVICE Fixed displacement pump Remove .
  • Page 428 Hydraulic systems - Fixed displacement pump Fixed displacement pump - General specification FILTER Type Full-flow spin on type Location On suction pipe before pump intake, on the right-hand side of the engine PUMP Type Gear type (In tandem with the steering pump), drawing oil from transmission housing Location On the right-hand side of the engine...
  • Page 429 Hydraulic systems - Fixed displacement pump Fixed displacement pump - Remove 1. Disconnect the power steering pipes on the hydraulic hump. GNIL14TR00729AA 2. Disconnect the hydraulic delivery pipe on the pump and remove the connector (1). GNIL14TR00730AA 3. Remove the hydraulic filter and connector between hy- draulic filter and pump.
  • Page 430 Hydraulic systems - Fixed displacement pump 5. Loosen the allen screws and remove the hydraulic pump. GNIL14TR00733AA 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 Index Hydraulic systems - 35 Fixed displacement pump - 104 Fixed displacement pump - General specification ......... . Fixed displacement pump - Install .
  • Page 433 47866583_ 02/12/2015 35.3 [35.104] / 8...

  • Page 434: [35.204] Remote Control Valves

    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 .
  • Page 436 Hydraulic systems - Remote control valves Remote control valve - Remove WARNING Escaping fluid! Lower the three-point hitch to the ground and relieve all pressure from the hydraulic system before installing the kit. Failure to comply could result in death or serious injury. W1114A 1.
  • Page 437 Hydraulic systems - 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 47866583_ 02/12/2015 35.4 [35.204] / 4...
  • Page 438 Hydraulic systems - Remote control valves Remote control valve - Remove WARNING Escaping fluid! Lower the three-point hitch to the ground and relieve all pressure from the hydraulic system before installing the kit. Failure to comply could result in death or serious injury. W1114A 1.
  • Page 439 Hydraulic systems - Remote control valves 4. Loosen the bolts (1) and remove the draft control lever (2). GNIL14TR00648AA 5. Loosen the bolt (1). GNIL14TR00658AA 6. Loosen the bolts (1). Remove the hoses (2). GNIL14TR00657AA 7. 1. Loosen the bolts (1). 2.
  • Page 440 Hydraulic systems - Remote control valves Remote control valve - Install WARNING Escaping fluid! Lower the three-point hitch to the ground and relieve all pressure 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.
  • Page 441 Hydraulic systems - Remote control valves Mid-mount remote control valve - Remove 1. Disconnect the two joystick cable from the mid-mount valve. See Joystick and Electric Hydraulic (EH) con- trol - Remove (55.512). 2. Disconnect the hydraulic delivery pipe between hy- draulic pump and mid-mount valve.
  • Page 442 Hydraulic systems - Remote control valves 5. Loosen the bolts (1) and remove the mid-mount valve from the mounting bracket. GNIL14TR00844AA 47866583_ 02/12/2015 35.4 [35.204] / 9...
  • Page 443 Hydraulic systems - Remote control valves Mid-mount remote control valve - Install 1. Install the mid-mount valve on the mounting bracket and tighten the bolts (1). GNIL14TR00844AA 2. Connect the hydraulic line between the mid-mount valve and hydraulic lift body. GNIL14TR00842AA 3.
  • Page 444 Index Hydraulic systems - 35 Remote control valves - 204 Mid-mount remote control valve - Install ........... Mid-mount remote control valve - Remove .
  • Page 445 47866583_ 02/12/2015 35.4 [35.204] / 12...

  • Page 446: [35.300] Reservoir, Cooler, And Filters

    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 .
  • Page 448 Hydraulic systems - Reservoir, cooler, and filters Oil filters - Remove 1. Loosen the clamp and remove the suction pipe from the hydraulic filter. GNIL14TR00725AA 2. Loosen the allen screws (1) and remove the hydraulic filter. GNIL14TR00728AA 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 ............... Oil filters - Remove .
  • Page 451 47866583_ 02/12/2015 35.5 [35.300] / 6...

  • Page 452: [35.355] Hydraulic Hand Control

    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 .
  • Page 454 Hydraulic filter is to be changed at regular intervals as recommended. Hydraulic and transmission parts may get damaged if filter is choked. Always use genuine NEW HOLLAND filters. GNIL14TR00580AA The system is operated by position control lever (1), draft control lever (2), and response control (3).
  • Page 455 Hydraulic systems - Hydraulic hand control Draft control operation Draft control is most suitable for mounted or semi- mounted implements operating in the ground. Changes in the working depth or changes in soil resistance will cause draft loading on the implement to increase or decrease.
  • Page 456 Hydraulic systems - Hydraulic hand control Hydraulic hand control - Disassemble WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 457 Hydraulic systems - Hydraulic hand control 4. 1. Remove draft control lever hub by loosening set screws (1) along with the nylon washer. 2. Remove sector plate. GNIL14TR04613AB 5. Draft 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.
  • Page 458 Hydraulic systems - Hydraulic hand control Hydraulic hand 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 47866583_ 02/12/2015 35.6 [35.355] / 7...
  • Page 459 Index Hydraulic systems - 35 Hydraulic hand control - 355 Hydraulic hand control - Assemble ............Hydraulic hand control - Disassemble .

  • Page 460: [35.359] Main Control Valve

    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) .
  • Page 462 Hydraulic systems - Main control valve Main control valve - Overview The distributor is pre-set to perform three phases. A. Neutral phase B. Lifting phase C. Lowering phase A. Neutral phase In this phase the control valve keeps pressure on the oil contained in the cylinder thus allowing the oil coming from the pump to flow freely to the tank.
  • Page 463 Hydraulic systems - Main control valve GNIL14TR00834GA 47866583_ 02/12/2015 35.7 [35.359] / 4...
  • Page 464 Hydraulic systems - Main control valve B. Lifting phase During this phase, the control valve supplies the oil under pressure to the cylinder (9) and it consequently lifts the arms. The control spool (1) is in such a position to connect the chamber (5) of the differential valve (2) with the oil coming from the pump through annular duct (8) and holes (12) and (13) making in this way the valve itself to close.
  • Page 465 Hydraulic systems - Main control valve C. Lowering phase During this phase, the control valve supplies at the same time the oil coming from the pump and the oil contained in the cylinder to the discharge causing the lowering of the arms. The control spool (1) is in such a position to connect chamber (5) of differential valve directly to the discharge through hole (6).
  • Page 466 Hydraulic systems - Main control valve GNIL14TR00836GA 47866583_ 02/12/2015 35.7 [35.359] / 7...
  • Page 467 Hydraulic systems - Main control valve Main control valve - Remove (Distributor assembly) WARNING 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, including protective goggles, gloves, and safety footwear.
  • 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 ............. . . Main control valve - Overview .
  • Page 470 47866583_ 02/12/2015 35.7 [35.359] / 11...
  • Page 471 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 472 SERVICE MANUAL Steering Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 473 Contents Steering - 41 [41.101] Steering control ..............41.1 [41.200] Hydraulic control components.

  • Page 474: Steering

    Steering - 41 Steering control - 101 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 41.1 [41.101] / 1...
  • Page 475 Contents Steering - 41 Steering control - 101 TECHNICAL DATA Steering control Special tools ................3 FUNCTIONAL DATA Steering control Overview –...
  • Page 476 Steering - Steering control Steering control - Special tools Description Tool number Steering wheel puller 380001672 and 380003008 Adapter, power steering pressure check 291318 (includes in the set of hydraulic pressure kit 292870) Power steering rotor spring installer 292927 47866583_ 02/12/2015 41.1 [41.101] / 3...
  • Page 477 Steering - Steering control Steering control - Overview – Hydrostatic steering GNIL14TR00870FA Hydraulic pump D1. Control valve Filter cartridge Return to tank Power cylinder Reservoir Pump outlet line Steering wheel 47866583_ 02/12/2015 41.1 [41.101] / 4...
  • Page 478 Steering - Steering control GNIL14TR04488JB 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 Steering - Steering control Operation in straight-ahead driving position Cover Right-hand side (Sd) and left-hand side (Ss) Spacer steer Right-hand side and left-hand side emergency 13, 14. Oil ports steer (Sed) and (Ses) Operation diagram for straight-ahead driving Rotor inlet passages ( 6 off) e, f.
  • Page 481 Steering - Steering control The control valve incorporates a metering unit which regulates the volume of oil supplied to the cylinder so that it is proportional to the angular movement of the steering wheel. The metering unit in combination with the check value also allows the steering to be operated manually without pressurised oil being supplied from the pump.
  • Page 482 Steering - Steering control 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 47866583_ 02/12/2015 41.1 [41.101] / 9...
  • Page 483 Adjust the play and, if necessary, shorten umn and steering unit input shaft the splines journal. Pinching between inner and outer spools Contact your authorised NEW HOLLAND “Motoring” effect. The Leaf springs are stuck or broken and have Replace leaf springs...
  • Page 484 Steering - Steering control Problem Possible Cause Correction “Shiny” - effect. The Air in the steering cylinder Bleed cylinder. Find and remove the rea- steered wheels vibrate. son for air collection (Rough tread on tires gives vibrations) Mechanical connections or wheel bearings Replace worn parts worn Steering wheel can be...
  • Page 485 Index Steering - 41 Steering control - 101 Steering control - Overview – Hydrostatic steering ......... . Steering control - Special tools .

  • Page 486: [41.200] Hydraulic Control Components

    Steering - 41 Hydraulic control components - 200 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 41.2 [41.200] / 1...
  • Page 487 Contents Steering - 41 Hydraulic control components - 200 SERVICE Hydraulic steering oil reservoir Remove ................. . 3 Power steering control valve Remove .
  • Page 488 Steering - Hydraulic control components Hydraulic steering oil reservoir - Remove 1. Lift the front hood. 2. Disconnect the hoses from the steering oil reservoir. GNIL14TR00758AA 3. Loosen the bolts and remove the steering oil reservoir. GNIL14TR00759AA 47866583_ 02/12/2015 41.2 [41.200] / 3...
  • Page 489 Steering - Hydraulic control components Power steering control valve - Remove 1. Position the tractor on a hard level surface and apply the parking brake. WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear.
  • Page 490 Steering - Hydraulic control components Power steering control valve - Disassemble 1. Hold the steering securely in a vice. 2. Remove the end cover bolts (6 plus one special screw). GNIL14TR04492AA 3. Remove the end cover, sideways. GNIL14TR04493AA 4. Lift the gear wheel set (with spacer fitted) off the unit. Take out the two O-rings.
  • Page 491 Steering - Hydraulic control components 6. Remove distributor plate. GNIL14TR04496AA 7. Screw out the threaded bush over the check valve. GNIL14TR04497AA 8. Remove O-ring. GNIL14TR04498AA 9. Shake out the check valve ball and suction valve pins and balls. NOTE: Replace pins prior to the reassembly. GNIL14TR04499AA 47866583_ 02/12/2015 41.2 [41.200] / 6...
  • Page 492 Steering - Hydraulic control components 10. Take care to keep the cross pin in the sleeve and spool horizontal. The pin can be seen through the open end of the spool. Press the spool inwards and the sleeve, ring, bearing races and needle bearing will be pushed out of the housing together.
  • Page 493 Steering - Hydraulic control components 13. Carefully press the spool out of the sleeve. GNIL14TR04504AA 14. Press the neutral position springs out of their slots in the spool. GNIL14TR04505AA 15. Remove dust seal and O-ring /kin-ring /roto glyd. GNIL14TR04506AA 16. The steering unit OSPB is now completely dismantled. GNIL14TR04507AA 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 Steering - Hydraulic control components Power steering control valve - Assemble WARNING 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, including protective goggles, gloves, and safety footwear.
  • Page 498 Steering - Hydraulic control components 4. Assemble spool and sleeve. GNIL14TR04511AA NOTE: When assembling spool and sleeve, only two pos- sible ways of positioning the spring slots are correct. There are three slots in the spool and three holes in the sleeve in the end of the spool/sleeve, opposite to the end with speing slots.
  • Page 499 Steering - Hydraulic control components 7. Guide the ring down over the sleeve. NOTE: The ring should be able to move - free of the springs. GNIL14TR04515AA 8. Fit the cross pin into the spool/sleeve. GNIL14TR04516AA 9. Fit bearing races and needle bearing as shown on be- low drawing.
  • Page 500 Steering - Hydraulic control components Assembly pattern for standard bearing 1. Outer bearing race 2. Needle bearing 3. Inner bearing race 4. Spool 5. Sleeve GNIL14TR04518AB *The inside chamfer on the inner bearing race must face the inner spool. Installation of O-ring 1.
  • Page 501 Steering - Hydraulic control components 2. Grease O-ring and king ring/roto glyd with hydraulic oil and place them on the tool. GNIL14TR04520AA 3. Hold the outer part of the assembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom.
  • Page 502 Steering - Hydraulic control components Installation of lip seal 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 mod- erate injury. C0044A 1. Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 503 Steering - Hydraulic control components 5. The spool set will push out the assembly tool guide. The O-ring and kin ring/roto glyd are now in position. GNIL14TR04528AA 6. Turn the steering unit until the bore is vertical again. Put the check valve ball into the hole indicated by the arrow.
  • Page 504 Steering - Hydraulic control components 9. Place a new pin in the same two holes. GNIL14TR04538AA 10. Grease the O-ring with mineral oil approximately vis- cosity 500 mm2/s at 20 °C (68 °F). GNIL14TR04532AA 11. Place the distributor plate so that the channel holes match the holes in the housing.
  • Page 505 Steering - Hydraulic control components 13. Place the cardan shaft as shown - so that it is held in position by mounting fork. GNIL14TR04535AA 14. Grease two O-rings with mineral oil approximately vis- cosity 500 mm2/s at 20 °C (68 °F) and place them in the two grooves in the gear rim.
  • Page 506 Steering - Hydraulic control components 16. Place the end cover in position. GNIL14TR04540AA 17. Fit the special screw with washer and place it in the hole (1). GNIL14TR04541AB 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 ±...
  • Page 507 Steering - Hydraulic control components 20. Press the plastic plugs into the connection ports. NOTE: Do not use a hammer. GNIL14TR04544AA 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 Steering - Hydraulic control components Steering circuit relief valve - Pressure test NOTE: There is no relief valve in steering pump and the following pressure test must only be performed as speci- fied below. Failure to observe this precaution may result in severe damage to the hydraulic pump.
  • Page 510 Steering - Hydraulic control components Steering circuit relief valve - Adjust NOTE: To adjust the steering system relief valve it is necessary to remove the steering motor from the steering bracket, to gain access to the hexagon headed adjusting screw. 1.
  • Page 511 Index Steering - 41 Hydraulic control components - 200 Hydraulic steering oil reservoir - Remove ..........Power steering control valve - Assemble .

  • Page 512: [41.206] Pump

    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 .
  • Page 514 Steering - Pump Power steering pump - General specification Type Gear type (In tandem with the hydraulic lift pump), drawing oil from steering oil reservoir 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...
  • 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 ..........Pump - Install .

  • Page 518: [41.216] Cylinders

    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 .
  • Page 520 Steering - Cylinders Steering cylinder - Remove – 2WD GNIL14TR04545FB 1. Stand the tractor on a hard level surface and position the front wheel in the straight ahead position. 2. Disconnect flexible pipes, cap the open pipe ends and remove hose clamps. NOTE: Position of flexible pipes and orientation of connec- tors must be the same upon re-assembly.
  • Page 521 Steering - Cylinders Steering cylinder - Overhaul GNIL14TR04546FB Seeger (5 and 7 also) 5. Ball joint Assembled rod 6. Head Piston 7. Nut 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).
  • Page 522 Steering - Cylinders 5. Remove the internal retaining ring with screw driver. 6. Remove the head hammering the rod. Remove the piston after unscrew the self locking nut. NOTE: Check that oil ports are not plugged and remove internal oil. GNIL14TR04547AA 7.
  • Page 523 Steering - Cylinders Installation of lip seal 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 mod- erate injury. C0044A 1. Lubricate the lip seal with hydraulic oil and place it on the assembly tool.
  • Page 524 Steering - Cylinders 5. Wash the head and verify whether the rags have been generated during disassembling and working GNIL14TR04556AA 6. Manual mount rod seal, taking care about the orienta- tion of the lips. (Oriented to retain oil). GNIL14TR04557AA 7. Mount manually the wiper (taking care about lip orien- tation) and the static seal (external).
  • Page 525 Steering - Cylinders Installation of lip seal 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 mod- erate injury. C0044A 1. Insert the head and piston on rod-screw self locking nut at torque (Nm).
  • 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 ..............Steering cylinder - Overhaul .
  • Page 528 47866583_ 02/12/2015 41.4 [41.216] / 11...
  • Page 529 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 530 SERVICE MANUAL Wheels Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 531 Contents Wheels - 44 [44.511] Front wheels................44.1 [44.520] Rear wheels .
  • 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 –...
  • Page 534 Wheels - Front wheels Front wheels - Test – 2WD Wheel camber test When 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.
  • Page 535 Wheels - Front wheels Front wheels - Toe in adjust – 2WD Front wheel toe-in test When the tractor moves along a straight line, wheels should be parallel to the tractor centre line or slightly toe-in until a max. of 0.50 mm (0.02 in), measured be- tween the rim edges.
  • Page 536 Wheels - Front wheels Front wheels - Adjust Tread adjustment 1. The front axle consists of a hollow center beam (1) with a telescopic section (2) at each end. Seven holes at 50 mm (1.97 in) intervals are provided in the telescopic sections for adjustment purposes.
  • Page 537 Wheels - Front wheels Securing Bolt Locations 1472 mm 1572 mm 1672 mm 1772 mm 1872 mm 1972 mm 4. Tighten the nuts on the axle extension securing bolts to 118 N·m (87 lb ft). With both front wheels parallel, install the locating bolt (2) in the nearest aligning notch in the tie rod.
  • Page 538 Wheels - Front wheels Front wheels - Adjust WARNING Roll-over hazard! Never operate the machine with a loose wheel rim or disc. Always tighten nuts and/or bolts to the specified torque value and at the recommended intervals. Failure to comply could result in death or serious injury. W0346B Tread setting Front...
  • Page 539 Wheels - Front wheels 1. Front wheel bolt torque: 192.0 N·m (141.6 lb ft) 76096164N-85X23 47866583_ 02/12/2015 44.1 [44.511] / 8...
  • Page 540 Index Wheels - 44 Front wheels - 511 Front wheels - Adjust ..............Front wheels - Adjust .
  • 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 Wheels - Rear wheels Rear wheel - Adjust Tread adjustment 1. Rear wheel track adjustment is done by changing the wheel rim relative to the center disc, the rim and/or the disc relative to the axle hub or by interchanging the rear wheels.
  • Page 545 Wheels - Rear wheels Rear disc to hub bolts 192 N·m (142 lb ft) Rear disc to rim nuts 239 N·m (176 lb ft) Rear Axle 2WD & 4WD Configuration 13.6 R 28 14.9 R 28 R4 18.4X24 1438.0 mm (56.6 in) 1336.0 mm (52.6 in) 1336.0 mm (52.6 in) 1420.0 mm (56 in)
  • Page 546 Index Wheels - 44 Rear wheels - 520 Rear wheel - Adjust ..............47866583_ 02/12/2015 44.2 [44.520] / 5...
  • Page 547 All rights reserved. No part of the text or illustrations of this publication may 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.
  • Page 548 SERVICE MANUAL Electrical systems Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015...
  • Page 549 Contents Electrical systems - 55 [55.000] Electrical system ..............55.1 [55.024] Transmission control system .

  • Page 550: Electrical Systems

    Electrical systems - 55 Electrical system - 000 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 55.1 [55.000] / 1...
  • Page 551 Contents Electrical systems - 55 Electrical system - 000 TECHNICAL DATA Electrical system General specification ............... 3 FUNCTIONAL DATA Electrical system Overview .
  • Page 552 Electrical systems - Electrical system Electrical system - General specification Main system protection Mega Fuse 125 A Number of fuses for protection Alternator 75 A Battery type 12 V Negative ground BCI group 47 CCA 600-850 Cold-start aid Starter motor - type Solenoid operated Starter kw (hp) rating 2.0 kW (2.7 Hp)
  • Page 553 Electrical systems - Electrical system Electrical system - Overview The electrical system of the tractor consists of various wiring harnesses, lights, switches, battery, alternator, starter and instrument cluster. Fuses (1) protect electrical circuits with thin pieces of wire, which heat up and melt when too much current flows through them.
  • Page 554 Electrical systems - Electrical system Electrical system - Troubleshooting Problem Possible Cause Correction Charge light remains Faulty alternator component. Test alternator and repair a necessary. illuminated Short circuit to ground between alternator Check wiring and repair as necessary. and warning lamp. Charge light does not Blown fuse panel, 15 A instrument panel Inspect 15 A fuse and replace as neces-...
  • Page 555 Index Electrical systems - 55 Electrical system - 000 Electrical system - General specification ..........Electrical system - Overview .

  • Page 556: [55.024] Transmission Control System

    Electrical systems - 55 Transmission control system - 024 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 55.2 [55.024] / 1...
  • Page 557 Contents Electrical 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 Electrical systems - Transmission control system Ground speed control - Test Transmission range safety switch Workmaster™ 50 Workmaster™ 60 NOTE: Use an ohmmeter to test the transmission range safety switch for electrical continuity. Extended position 1. With the transmission range safety switch plunger in the extended position "A", there will be electrical continuity across the terminal leads.
  • Page 559 Index Electrical systems - 55 Transmission control system - 024 Ground speed control - Test Transmission range safety switch (*) ......(*) 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 Contents Electrical systems - 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 .
  • Page 562 Electrical systems - Rear Power Take-Off (PTO) control system Power Take-Off (PTO) speed sensor - Static description PTO Safety switch The PTO safety switch, (1), is a double 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.
  • Page 563 Electrical systems - Rear Power Take-Off (PTO) control system Power Take-Off (PTO) speed sensor - Remove 1. Remove the fender from left side of the tractor. See Fenders and guards - Remove (90.116). 2. Loosen the bolts (1). GNIL14TR00840AA 3. Lift the plate (1) access the wire connector. 4.
  • Page 564 Electrical systems - Rear Power Take-Off (PTO) control system Power Take-Off (PTO) speed sensor - Install 1. Connect the wiring (1). GNIL14TR00838AA 2. Fit the PTO sensor and tighten the nut (1). 3. Tighten the bolts (2). GNIL14TR00839AA 4. Install the plate (1). Tighten the bolts (2). GNIL14TR00840AA 47866583_ 02/12/2015 55.3 [55.048] / 5...
  • Page 565 Index Electrical systems - 55 Rear Power Take-Off (PTO) control system - 048 Power Take-Off (PTO) speed sensor - Install ..........Power Take-Off (PTO) speed sensor - Remove .

  • Page 566: [55.100] Harnesses And Connectors

    Electrical systems - 55 Harnesses and connectors - 100 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 55.4 [55.100] / 1...
  • Page 567 Contents Electrical systems - 55 Harnesses and connectors - 100 FUNCTIONAL DATA Wiring harnesses Electrical schematic sheet 02 SH02-POWER DISTRIBUTION:GEP FUSE BOX ....4 Electrical schematic sheet 03 SH03-STARTING/CHARGING SYSTEM .
  • Page 568 Component diagram 90 ..............69 Component diagram 00 - Connectors X-9001 to X-9009 .
  • Page 569 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 02 SH02-POWER DISTRIBUTION:GEP FUSE BOX Type Component Connector / Link Description Fuse F-002 F-002 GEP - FUSE BOX Fuse F-003 FUSE ECU 01 Fuse F-004 FUSE ECU 02 Fuse F-005 LAMBDA PROBES...
  • Page 570 Electrical systems - Harnesses and connectors SHT_2 47866583_ 02/12/2015 55.4 [55.100] / 5...
  • Page 571 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 03 SH03-STARTING/ CHARGING SYSTEM Type Component Connector / Link Description Fuse F-001 X-015 X-017 MEGA FUSE Voltage source G-001 X-001A X-001B BATTERY Voltage source G-002 X-209 ALTERNATOR Motor M-001 RT001 X-004A X-206 STARTER MOTOR...
  • Page 572 Electrical systems - Harnesses and connectors SHT_3 47866583_ 02/12/2015 55.4 [55.100] / 7...
  • Page 573 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 04 SH04-POWER DISTRIBUTION:GEP RELAY BOX Type Component Connector / Link Description Fuse F-002 F-002 GEP - FUSE BOX Relay K-003 ING RELAY 01 Relay K-004 ING RELAY 02 Relay K-005 W LAMP...
  • Page 574 Electrical systems - Harnesses and connectors SHT_4 47866583_ 02/12/2015 55.4 [55.100] / 9...
  • Page 575 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 05 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 X-002D...
  • Page 576 Electrical systems - Harnesses and connectors SHT_5 47866583_ 02/12/2015 55.4 [55.100] / 11...
  • Page 577 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 06 SH06-IGNITION/ CONTROL SWITCHES Type Component Connector / Link Description Fuse F-003 FUSE ECU 01 Fuse F-015 FLASHER Fuse F-016 CLUSTER / FT Fuse F-017 HAZARD HOT Fuse F-018 HORN/ LIGHT SW Fuse...
  • Page 578 Electrical systems - Harnesses and connectors SHT_6 47866583_ 02/12/2015 55.4 [55.100] / 13...
  • Page 579 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 07 SH07-INSTRUMENT CLUSTER: ADIC Type Component Connector / Link Description Switch S-007 X-018 X-019 HOME/ENTER Switch S-008 X-020 X-021 UP/DOWN Connector X-018 X-018 HOME ENTER SWITCH Connector X-019 X-019 SWITCH LAMP H/E X-020...
  • Page 580 Electrical systems - Harnesses and connectors SHT_7 47866583_ 02/12/2015 55.4 [55.100] / 15...
  • Page 581 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 08 SH08-ENGINE CONTROL UNIT: ECU Type Component Connector / Link Description Connector X-003 X-003 IGNITION SWITCH Connector X-026 X-026 SENSOR WATER IN FUEL Connector X-027 X-027 PRE HEATER Connector X-101 X-101...
  • Page 582 Electrical systems - Harnesses and connectors SHT_8 47866583_ 02/12/2015 55.4 [55.100] / 17...
  • Page 583 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 09 SH09-SAFETY LOGIC Type Component Connector / Link Description Fuse F-002 F-002 GEP - FUSE BOX Connector X-014 X-014 SAFETY BUZZER Connector X-016 X-016 BRAKE SWITCH Connector X-025 X-025 CLUTCH SWITCH Connector...
  • Page 584 Electrical systems - Harnesses and connectors SHT_9 47866583_ 02/12/2015 55.4 [55.100] / 19...
  • Page 585 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 10 SH10-FRONT HEAD LIGHTS Type Component Connector / Link Description 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 X-302 X-302 HEADLAMP LH...
  • Page 586 Electrical systems - Harnesses and connectors SHT_10 47866583_ 02/12/2015 55.4 [55.100] / 21...
  • Page 587 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 11 SH11-REAR LIGHTS Type Component Connector / Link Description Connector X-011 X-011 TURN FLASHER 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...
  • Page 588 Electrical systems - Harnesses and connectors SHT_11 47866583_ 02/12/2015 55.4 [55.100] / 23...
  • Page 589 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 12 SH12-DIAGONESTIC/ TRAILER SOCKET Type Component Connector / Link Description Connector 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 X-602B X-602B...
  • Page 590 Electrical systems - Harnesses and connectors SHT_12 47866583_ 02/12/2015 55.4 [55.100] / 25...
  • Page 591 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 01 – Power distribution 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.
  • Page 592 Electrical systems - Harnesses and connectors NHIL15ENG0123JA 47866583_ 02/12/2015 55.4 [55.100] / 27...
  • Page 593 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 02 – Engine Control Unit (ECU) power and after treatment system (engine schematics) Component Identifier Description A-9000 Engine Control Unit (ECU) B-9123 Lambda (Universal Heated Exhaust Gas Oxygen (UHEGO) sensor B-9126 Diesel Oxidation Catalyst (DOC) inlet temperature sensor...
  • Page 594 Electrical systems - Harnesses and connectors NHIL15ENG0154JA 47866583_ 02/12/2015 55.4 [55.100] / 29...
  • Page 595 Electrical systems - Harnesses and connectors Wiring harnesses - Electrical schematic sheet 03 – Engine sensors and fuel injection (engine schematics) Component identifier Description A-9000 Engine Control Unit (ECU) B-9001 Intake manifold pressure and temperature sensor B-9002 Fuel temperature sensor B-9003 Coolant temperature sensor B-9004...
  • Page 596 Electrical systems - Harnesses and connectors NHIL15ENG0155JA 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 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 00 X-001 - (84380518) (Female) 84380518 84380518 From Wire Description Color-Size Frame SP-019-P-X 009R 009R BK - 0.75 SHEET 04 SP-013-P-X RD - 3.0 009L 009L BK - 0.5 SP-019-P-X SP-069-P-X 069B...
  • Page 599 Electrical systems - Harnesses and connectors X-001B - [ G-001] (Male) From Wire Description Color-Size Frame PIN1 X-002A (Male) pin PIN1 BATTERY CABLE BK - 40.0 SHEET 03 GROUND TERMINAL GROUND X-002A - GROUND TERMINAL (Male) From Wire Description Frame Color-Size PIN1 X-001B pin PIN1...
  • Page 600 Electrical systems - Harnesses and connectors X-002D - ECU/ENGINE GROUND (84179566) (Male) 84179566 84179566 From Wire Description Color-Size Frame SP-009-P-X ECU/ENGINE GROUND BK - 6.0 SHEET 05 X-003 - IGNITION SWITCH [ S-001] (84479009) (Female) 84479009 84479009 From Wire Description Color-Size Frame SP-106-P-X...
  • Page 601 Electrical systems - Harnesses and connectors X-004A - [ M-001] (Male) From Wire Description Color-Size Frame PIN1 X-001A (Male) pin PIN1 BATTERY CABLE RD - 40.0 SHEET 03 POSITIVE X-005 - LIGHT SWITCH (84179574) (Female) 84179574 84179574 From Wire Description Frame Color-Size SP-060-P-X...
  • Page 602 Electrical systems - Harnesses and connectors X-007 - HORN SWITCH CN1 (87581782) (Female) 87581782 87581782 From Wire Description Color-Size Frame SP-029-P-X 029B 029B GN/OR - 0.75 SHEET 06 X-008 - HORN SWITCH CN2 (87581782) (Female) 87581782 87581782 From Wire Description Color-Size Frame X-406A-P-12...
  • Page 603 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 01 X-011 - TURN FLASHER (47781082) (Male) 47781082 47781082 X-012 - TURN SWITCH (84179572) (Female) 84179572 84179572 From Wire Description Color-Size Frame F-003-P-1 MINI FUSER TURN/STOP LAMP LG - 0.75 SHEET 06 X-011 pin 8 TURN FLASHER 061 LG/BL - 0.75...
  • Page 604 Electrical systems - Harnesses and connectors X-014 - SAFETY BUZZER (87700098) (Female) 87700098 87700098 From Wire Description Color-Size Frame SP-025-P-X 031B 031B RD/BL - 0.75 SHEET 09 X-406B pin 8 TO MAIN BL - 0.75 HARNESS SP-159-P-X 159B 159B PK/WH - 0.5 009T 009T BK - 0.5...
  • Page 605 Electrical systems - Harnesses and connectors From Wire Description Color-Size Frame SP-051-P-X 051A 051A YE/RD - 0.75 SHEET 09 SP-156-P-X GY - 0.75 X-017 - FROM MEGA FUSE [ F-001] (84488487) (Male) 84488487 84488487 From Wire Description Color-Size Frame SP-007-P-X RD - 8.0 SHEET 03 X-018 - HOME ENTER SWITCH [ S-007] (87745329) (Female)
  • Page 606 Electrical systems - Harnesses and connectors X-019 - SWITCH LAMP H/E [ S-007] (84131048) (Female) 84131048 84131048 From Wire Description Color-Size Frame SP-059-P-X BL/BK - 0.75 SHEET 07 SP-006-P-X 005G 005G BK - 0.75 47866583_ 02/12/2015 55.4 [55.100] / 41...
  • Page 607 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 02 X-020 - UP/DOWN SWITCH [ S-008] (87745329) (Female) 87745329 87745329 From Wire Description Color-Size Frame X-050 (Female) pin 22 NAVIGATION SW DWN PK/BK - 0.75 SHEET 07 INSTRUMENT CLUSTER CN-1 SP-006-P-X 005H...
  • Page 608 Electrical systems - Harnesses and connectors X-022 - FOOT THROTTLE (87694109) (Female) 87694109 87694109 From Wire Description Color-Size Frame X-402A-P-8 FOOT THROTTLE PK - 1.0 SHEET 07 X-402A-P-7 FOOT THROTTLE BK - 1.0 X-402A-P-9 FOOT THROTTLE GY/BL - 1.0 X-402A-P-6 FOOT THROTTLE YE/GN - 1.0 X-402A-P-5...
  • Page 609 Electrical systems - Harnesses and connectors X-025 - CLUTCH SWITCH (84182898) (Female) 84182898 84182898 From Wire Description Color-Size Frame X-502 (Female) pin 3 PTO GN/BK - 0.75 SHEET 09 SWITCH X-402A-P-4 YE - 0.75 X-026 - SENSOR WATER IN FUEL (87709663) (Female) 87709663 87709663 From...
  • Page 610 Electrical systems - Harnesses and connectors X-028 - FRONT LOADER (82012083) (Female) 82012083 82012083 From Wire Description Color-Size Frame F-002-Female-P-33 GEP - OR/GN - 1.0 SHEET 02 FUSE BOX SP-009-P-X 009X 009X BK - 1.0 47866583_ 02/12/2015 55.4 [55.100] / 45...
  • Page 611 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 05 X-050 - INSTRUMENT CLUSTER CN-1 (82028493) (Female) 82028493 82028493 From Wire Description Color-Size Frame X-507 (Female) pin 2 FUEL FUEL SENDER UNIT BL - 0.75 SHEET 07 SENDER UNIT SP-015-P-X CAN HIGH YE - 0.75...
  • Page 612 Electrical systems - Harnesses and connectors From Wire Description Color-Size Frame X-402B pin 8 MAIN-FENDER PK - 1.0 SHEET 07 INTERCONNECT X-404A-P-18 AIR CLOG BL/RD - 0.5 SP-060-P-X 060B HIGH BEAM BL/YE - 0.75 SP-124-P-X PARKING BRAKE YE/BK - 0.5 SP-119-P-X 119B INDICATOR TURN LEFT...
  • Page 613 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 10 X-101 - GCU (84356962) (Female) 84356962 84356962 From Wire Description Color-Size Frame X-207 (Female) pin C TO RD/GN - 1.5 SHEET 08 ENGINE GLOW PLUGS X-201 (Female) pin 22 ECU BR - 0.75 VEHICLE SP-007-P-X...
  • Page 614 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 20 X-201 - ECU VEHICLE (87745798) (Female) 87745798 87745798 From Wire Description Color-Size Frame F-002-P-6 GEP - FUSE BOX OR/BL - 2.5 SHEET 08 SP-018-P-X BK - 2.5 012A 012A SP-012-P-X OR/BL - 2.5...
  • Page 615 Electrical systems - Harnesses and connectors X-206 - TO STARTER MOTOR [ M-001] (87581782) (Female) 87581782 87581782 From Wire Description Color-Size Frame SP-004-P-X 004B 004B PK - 2.5 SHEET 03 X-207 - TO ENGINE GLOW PLUGS (87693326) (Female) 87693326 87693326 From Wire Description...
  • Page 616 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 21 X-211 - AIR CLOG SWITCH (87581782) (Female) 87581782 87581782 From Wire Description Color-Size Frame SP-009-P-X 009J 009J BK - 0.5 SHEET 05 X-212 - LAMBDA SENSOR (84301132) (Female) 84301132 84301132 From...
  • Page 617 Electrical systems - Harnesses and connectors X-213 - AIR CLOG SWITCH (87581782) (Female) 87581782 87581782 From Wire Description Color-Size Frame X-404B pin 18 MAIN-ENGINE AIR CLOG SENSOR BL/RD - 0.5 SHEET 07 INTERCONNECT X-214 - INLET DOC TEMP SENSOR (87709793) (Female) 87709793 87709793 From...
  • Page 618 Electrical systems - Harnesses and connectors X-216B - HEADLAMP INTERCONNECT (47405381) (Female) 47405381 47405381 From Wire Description Color-Size Frame X-001 pin 45 GN/YE - 1.5 SHEET 10 X-406B pin 12 TO MAIN YE/BL - 1.0 SHEET 06 HARNESS 009D 009D BK - 1.0 SP-009-P-X SHEET 05...
  • Page 619 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 30 X-301 - HEADLAMP RH (87697641) (Female) 87697641 87697641 From Wire Description Color-Size Frame SP-102-P-X 102B 102B GY - 1.0 SHEET 10 SP-103-P-X 103D 103D BK - 1.0 104B 104B SP-104-P-X GN/YE - 1.5...
  • Page 620 Electrical systems - Harnesses and connectors From Wire Description Color-Size Frame SP-105-P-X 105B 105B OR - 1.5 SHEET 10 SP-103-P-X 103E 103E BK - 1.0 X-304 - WORKLAMP LH (82003123) (Female) 82003123 82003123 From Wire Description Color-Size Frame SP-105-P-X 105A 105A OR - 1.5 SHEET 10...
  • Page 621 Electrical systems - Harnesses and connectors From Wire Description Color-Size Frame SP-103-P-X 103C 103C BK - 1.0 SHEET 10 47866583_ 02/12/2015 55.4 [55.100] / 56...
  • Page 622 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 40 X-400A - MAIN-FENDER INTERCONNECT (47731490) (Female) 47731490 47731490 X-402B - MAIN-FENDER INTERCONNECT (47731489) (Female) 47731489 47731489 X-404B - MAIN-ENGINE INTERCONNECT (47731487) (Female) 47731487 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 47731489 47866583_ 02/12/2015 55.4 [55.100] / 58...
  • Page 624 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 50 X-502 - PTO SWITCH (84488490) (Female) 84488490 84488490 From Wire Description Color-Size Frame SP-051-P-X 051B 051B YE/RD - 0.75 SHEET 09 SP-051-P-X 051C 051C YE/RD - 0.75 X-025 (Female) pin 1 CLUTCH GN/BK - 0.75 SWITCH X-400B-P-11...
  • Page 625 Electrical systems - Harnesses and connectors X-504 - PARKING BRAKE SWITCH (84182898) (Female) 84182898 84182898 From Wire Description Color-Size Frame X-402A-P-10 RD - 0.5 SHEET 09 X-402A-P-2 YE/BK - 0.5 X-505 - HI/LOW SWITCH [ HI-LOW SWITCH] (82012083) (Female) 82012083 82012083 From Wire...
  • Page 626 Electrical systems - Harnesses and connectors From Wire Description Color-Size Frame X-505 (Female) pin 1 HI/LOW YE/GN - 0.75 SHEET 09 SWITCH X-402A-P-3 VT - 0.75 X-507 - FUEL SENDER UNIT (82012083) (Female) 82012083 82012083 From Wire Description Color-Size Frame 140B BK - 1.0 SP-140-P-X...
  • Page 627 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 51 X-515A - TO JOYSTICK PIGTAIL (82012083) (Female) 82012083 82012083 From Wire Description Color-Size Frame X-400B-P-9 BL/YE - 0.5 SHEET 06 SP-010-P-X 010D 010D BK - 0.5 X-516 - BECON LAMP (84182898) (Female) 84182898 84182898 From...
  • Page 628 Electrical systems - Harnesses and connectors From Wire Description Color-Size Frame SP-024-P-X 025C 025C PK - 1.5 SHEET 11 SP-014-P-X 164D 164D BK - 0.75 X-518 - LICENCE LAMP (82000579) (Female) 82000579 82000579 From Wire Description Color-Size Frame SP-020-P-X RD/WH - 0.5 SHEET 11 SP-014-P-X 164C...
  • Page 629 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 52 X-520 - LOADER JOYSTICK [ S-009] (87715977) (Female) 87715977 87715977 From Wire Description Color-Size Frame X-515B-Male-P-2 0002 0002 BK - 0.5 SHEET 06 X-515B-Male-P-1 0001 0001 BL/YE - 0.5 47866583_ 02/12/2015 55.4 [55.100] / 64...
  • Page 630 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 60 X-602A - TO TRAILER HARNESS (84253498) (Female) 84253498 84253498 From Wire Description Color-Size Frame SP-163-P-X YE - 0.75 SHEET 11 SP-010-P-X 010A 010A BK - 1.0 SHEET 05 SP-161-P-X OR - 0.75 SHEET 11...
  • Page 631 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 61 X-612 - ROPE LAMP RH (84182907) (Male) 84182907 84182907 From Wire Description Color-Size Frame SP-014-P-X 164B 164B BK - 0.75 SHEET 11 SP-020-P-X BL/BK - 0.75 X-613 - ROPE LAMP LH (84182907) (Male) 84182907 84182907 From...
  • Page 632 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 70 X-702A - TO DIAGONESTIC SOCKET (47511905) (Female) 47511905 47511905 47866583_ 02/12/2015 55.4 [55.100] / 67...
  • Page 633 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 71 X-712 - ALTERNATOR B+ (84488486) (Male) 84488486 84488486 From Wire Description Color-Size Frame X-713 (Male) pin 1 TO ALTERNATOR CABLE RD - 16.0 SHEET 03 STARTER MOTOR X-713 - TO STARTER MOTOR (84488486) (Male) 84488486 84488486 From...
  • Page 634 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 90 X-901 - ALTERNATOR B+ (84488487) (Male) 84488487 84488487 From Wire Description Color-Size Frame X-015 (Male) pin 1 TO MEGA RD - 8.0 SHEET 03 FUSE X-902 - TRAILER SOCKET (84531642) (Male) 84531642 84531642 From...
  • Page 635 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 00 - Connectors X-9001 to X-9009 Connector X-9001 - Engine Control Unit (ECU) connector A 84474053 84474053 CONNECTOR X-9001 - ECU connector A WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9128 High Side Driver (HSD), Bank 2...
  • Page 636 Electrical systems - Harnesses and connectors CONNECTOR X-9001 - ECU connector A WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9110 Reference ground, Camshaft speed SHEET 03 sensor EN-9128 Low Side Driver (LSD), Bank 2 SHEET 03 Injector 1 (Cylinder 3) EN-9126 LSD, Bank 1 Injector 1 (Cylinder 1) EN-9135...
  • Page 637 Electrical systems - Harnesses and connectors Connector X-9003 - Intake manifold pressure and temperature sensor 87709809 87709809 CONNECTOR X-9003 - Intake manifold pressure and temperature sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9103 Engine Control Unit (ECU) reference SHEET 03 ground, pressure and temperature EN-9104...
  • Page 638 Electrical systems - Harnesses and connectors Connector X-9006 - Coolant temperature sensor 87709793 87709793 CONNECTOR X-9006 - Coolant temperature sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9115 Engine Control Unit (ECU) input SHEET 03 signal, temperature EN-9114 ECU reference ground Connector X-9007 - Fuel metering unit 87709793 87709793...
  • Page 639 Electrical systems - Harnesses and connectors Connector X-9008 - Camshaft phase sensor 87709793 87747172 CONNECTOR X-9008 - Camshaft phase sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9110 Reference ground, Engine Control SHEET 03 Unit (ECU) EN-9111 Input signal, ECU EN-9109 +5 V sensor supply, ECU 47866583_ 02/12/2015...
  • Page 640 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 01 - Connectors X-9010 to X-9019 Connector X-9011 - Throttle Valve Actuator (TVA) 84360293 84360293 CONNECTOR X-9011 - TVA WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9098 +5 V sensor supply, Engine Control SHEET 03 Unit (ECU) EN-9135...
  • Page 641 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 02 - Connectors X-9020 to X-9029 Connector X-9026 - Rail pressure sensor 84130322 84146683 CONNECTOR X-9026 - Rail pressure sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9106 Reference ground, Engine Control SHEET 03 Unit (ECU)
  • Page 642 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 03 - Connectors X-9030 to X-9039 Connector X-9030 - Cylinder 1 injector (Bank 1 Injector 1) 87709793 87709793 CONNECTOR X-9030 - Cylinder 1 injector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9125 High Side Driver (HSD), Engine...
  • Page 643 Electrical systems - Harnesses and connectors Connector X-9032 - Cylinder 2 injector (Bank 1 injector 2) 87709793 87709793 CONNECTOR X-9032 - Cylinder 2 injector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9129 High Side Driver (HSD), Engine SHEET 03 Control Unit (ECU) EN-9130 Low Side Driver (LSD), Engine...
  • Page 644 Electrical systems - Harnesses and connectors Connector X-9035 - Cylinder 2 glow plug 1-928-404-879 1-928-404-879 CONNECTOR X-9035 - Cylinder 2 glow plug WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER GP-2 Glow plug supply SHEET 01 Connector X-9036 - Cylinder 3 glow plug 1-928-404-879 1-928-404-879 CONNECTOR X-9036 - Cylinder 3 glow plug...
  • Page 645 Electrical systems - Harnesses and connectors CONNECTOR X-9039 - Crankshaft speed sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER EN-9138 Input signal, positive, Engine Control SHEET 03 Unit (ECU) EN-9139 Input signal, negative, Engine Control Unit (ECU) EN-9140 Reference ground, Engine Control Unit (ECU) 47866583_ 02/12/2015 55.4 [55.100] / 80...
  • Page 646 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 10 - Connectors X-9101 to X-9109 Connector X-9102 - Engine Control Unit (ECU) connector K 84474047 84474047 CONNECTOR X-9102 - ECU connector K WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER VE-9083 Main relay switched fused supply,...
  • Page 647 Electrical systems - Harnesses and connectors CONNECTOR X-9102 - ECU connector K WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER VE-9174 LSD, Starter control relay SHEET 02 VE-9084 LSD, Main relay VE-9074 Reference ground, GCU SHEET 02 VE-9072 LSD, GCU SHEET 02 VE-9173 HSD, Starter control relay...
  • Page 648 Electrical systems - Harnesses and connectors CONNECTOR X-9102 - ECU connector K WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER VE-9188 Reference ground, Exhaust gas SHEET 02 temperature DOC sensor VE-9147 Input signal, Exhaust gas temperature DOC sensor VE-9153 Reference ground, Exhaust gas SHEET 02 temperature POC sensor VE-9152...
  • Page 649 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 11 - Connectors X-9110 to X-9119 Connector X-9113 - Glow-plugs control unit 84356962 84356962 CONNECTOR X-9113 - Glow-plugs control unit WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER VE-9060 High Side Driver (HSD), Glow-plug 3 SHEET 01 VE-9058...
  • Page 650 Electrical systems - Harnesses and connectors Wire connectors - Component diagram 12 - Connectors X-9120 to X-9129 Connector X-9120 - ECU start relay NOTE: Relays are in product relay panels. See product service manual for pinout image of this connector. CONNECTOR X-9120 - ECU start relay WIRE NUMBER CIRCUIT REFERENCE...
  • Page 651 Electrical systems - Harnesses and connectors Connector X-9125 - Water in fuel sensor 84806091 84806091 CONNECTOR X-9125 - Water in fuel sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER VE-9077 Input signal, Engine Control Unit SHEET 02 (ECU) VE-9085 Switched source voltage, Main ECU power relay VE-9078...
  • Page 652 Electrical systems - Harnesses and connectors Connector X-9127 - Exhaust gas temperature Pre-Oxidation Catalyst (POC) sensor 87709793 87709793 CONNECTOR X-9127 - Exhaust gas temperature POC sensor WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER VE-9152 Input signal, Engine Control Unit SHEET 02 (ECU) VE-9153...
  • Page 653 Electrical systems - Harnesses and connectors Electrical components - Fuse description F-001 - MEGA FUSE (Fuse) Component Type Fuse Wiring frames SHEET 03 Connectors X-015 (Male) X-017 (Male) F-002 - GEP - FUSE BOX (Fuse) Component Type Fuse Wiring frames SHEET 02 SHEET 04 SHEET 05...
  • Page 654 Electrical systems - Harnesses and connectors F-012 - ECU/SAFETY START (Fuse) Component Type Fuse Wiring frames SHEET 02 F-013 - DUMMY1 (Fuse) Component Type Fuse Wiring frames SHEET 02 F-014 - DUMMY2 (Fuse) Fuse Component Type Wiring frames SHEET 02 F-015 - FLASHER (Fuse) Fuse Component Type...
  • Page 655 Electrical systems - Harnesses and connectors Electrical components - Voltage source 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)
  • Page 656 Electrical systems - Harnesses and connectors Electrical components - Relay description K-001 - ECU POWER (Relay) Component Type Relay Wiring frames SHEET 02 K-002 - CRANKING RELAY (Relay) Component Type Relay Wiring frames SHEET 02 K-003 - ING RELAY 01 (Relay) Relay Component Type Wiring frames...
  • Page 657 Electrical 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 Electrical systems - 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 Electrical systems - Harnesses and connectors Electrical components - Switch description S-001 - IGNITION SWITCH (Switch) Component Type Switch Wiring frames SHEET 06 Connectors 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...
  • Page 660 Electrical systems - Harnesses and connectors Wiring harnesses - Repair Temporary wiring harness repair The following method to repair wiring is a temporary expedient only. Wiring should be replaced as soon as possible. Replacement of temporary repaired cables with new is particularly important if the tractor is to be used for puddling, spraying etc, as water/chemicals can enter the repaired area, travel up the cable and damage electrical components.
  • Page 661 Electrical systems - Harnesses and connectors 6. Allow the compound to cure, then cover the area with insulating tape taking the tape well over each end of the repair. An overlap of at least 50.00 mm (1.97 in) of tape at each end is necessary, figure 4. 7.
  • Page 662 Electrical systems - Harnesses and connectors Wiring harnesses - Troubleshooting Safety start circuit - Operator present Problem Possible Cause Correction Starter motor will not Insufficient battery charge. Test battery. Charge, add water, or replace energize as necessary. Blown fusible link. Inspect and replace fusible link as neces- sary.
  • Page 663 Electrical systems - Harnesses and connectors Wiring harnesses - Troubleshooting Safe Operation - Operator Present Problem Possible Cause Correction Engine does not continue Defective seat safety switch. Test seat safety switch and replace as nec- to run while operator is essary.
  • Page 664 Electrical systems - Harnesses and connectors Problem Possible Cause Correction Blown 3 A diode. Check diode, replace if necessary. Malfunctioning fuel shutoff solenoid. Test fuel shutoff solenoid and replace as necessary. Defective operator safety module. Test module and replace as necessary. Open wiring in safe operation circuit.
  • Page 665 Index Electrical systems - 55 Harnesses and connectors - 100 Wiring harnesses - Electrical schematic sheet 03 SH03-STARTING/CHARGING SYSTEM ..Wiring harnesses - Electrical schematic sheet 04 SH04-POWER DISTRIBUTION:GEP RELAY BOX ..................Wiring harnesses - Electrical schematic sheet 05 SH05-GROUNDING SYSTEM .
  • Page 666 Wire connectors - Component diagram 21 ..........Wire connectors - Component diagram 30 .
  • Page 667 47866583_ 02/12/2015 55.4 [55.100] / 102...

  • Page 668: [55.201] Engine Starting System

    Electrical systems - 55 Engine starting system - 201 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 55.5 [55.201] / 1...
  • Page 669 Contents Electrical systems - 55 Engine starting system - 201 FUNCTIONAL DATA Engine starting system Dynamic description ............... . 3 SERVICE Engine starter Remove .
  • Page 670 Electrical systems - Engine starting system Engine starting system - Dynamic description Description of operation The starting system consists of a starter motor equipped with an electromagnetic starter solenoid, a key switch, a start relay, several safety switches, and heavy-duty wiring. Starter components SEC55CH4PG28 (1) Reduction Uni Cover...
  • Page 671 Electrical systems - Engine starting system Starter solenoid The starter solenoid is an electromagnetic type solenoid that is located on the bottom of the starter motor assem- bly. The solenoid contains two coils, a pull-in coil, (1) and a hold-in coil (2) When the key switch is turned to the "START"...
  • Page 672 Electrical systems - Engine starting system Engine starter - Remove 1. Lift the front hood. Disconnect the battery terminals (Negative first). 2. Disconnect the electrical connection from the starter motor. GNIL14TR00713AA 3. Remove the set screw (1) on the front axle support. It interferes while the starter motor mounting bolts are loosened.
  • 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 Electrical systems - Engine starting system Engine starter - Troubleshooting Problem Possible Cause Correction Pinion shaft fails to Wiring: Open circuit battery, and switch ter- Repair or replace. advance minal connections. Wiring: Open circuit, fuse. Replace fuse. Key switch: No contact. Repair or replace.
  • Page 675 Index Electrical systems - 55 Engine starting system - 201 Engine starter - Install ..............Engine starter - Remove .

  • Page 676: [55.301] Alternator

    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 Electrical systems - Alternator Alternator - Troubleshooting Problem Possible Cause Correction No charging Wiring: Loose connection or short circuit. Repair. Alternator: Loose connection, no ground, Repair or replace. or short circuit. Alternator: Defective rectifier. Replace. Regulator: Defective regulator. Replace. Regulator: Loose connection of alternator Repair or replace.
  • Page 679 Index Electrical systems - 55 Alternator - 301 Alternator - Troubleshooting ............. 47866583_ 02/12/2015 55.6 [55.301] / 4...

  • Page 680: [55.302] Battery

    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 .
  • Page 682 Electrical systems - Battery Battery - Remove WARNING Improper operation or service of this machine can result in an accident. Before working on any component(s) of the electrical circuit, put the starter switch key in the off (shut down) position. When disconnecting batteries, always disconnect the negative (-) cable first. When reconnecting batteries, always connect the negative (-) cable last.
  • Page 683 Electrical systems - Battery Battery - Check DANGER Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply will result in death or serious injury.
  • Page 684 Electrical systems - Battery Battery - Install 1. Check the battery for cleanliness, especially around the terminals. Clean the area where the battery mounts to the tractor frame to prevent debris from piercing the body of the battery. 2. Check the vent caps for proper installation and tight- ness.
  • Page 685 Index Electrical systems - 55 Battery - 302 Battery - Check ............... . Battery - Install .

  • Page 686: [55.404] External Lighting

    Electrical systems - 55 External lighting - 404 Workmaster™ 50 Workmaster™ 60 Workmaster™ 70 47866583_ 02/12/2015 55.8 [55.404] / 1...
  • Page 687 Contents Electrical systems - 55 External lighting - 404 SERVICE Headlight Replace ................. . . 3 Turn signal and/or hazard lights Replace .
  • Page 688 Electrical systems - External lighting Headlight - Replace 1. Remove the electrical connector (1) GNIL14TR00534AA 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 Electrical systems - External lighting Turn signal and/or hazard lights - Replace Stop/Turn/Position lights, bulb replacement The bulbs are accessible after removal of the plastic lenses assembly. Remove the two screws (1) and take out the lens assembly (2). The bulbs can be removed by pressing in and turning approximately 20 degree counterclockwise.

  • Page 690: Troubleshooting Lighting Circuit

    Electrical systems - External lighting External lighting - Troubleshooting Lighting circuit Problem Possible Cause Correction Front road lamps will not Insufficient battery charge. Test battery. Charge, add water, or replace illuminate or are dim as necessary. Road lamp bulb faulty. Check and replace bulb as necessary.

  • Page 691: Turn Signal And/Or Hazard Lights

    Electrical systems - External lighting Turn signal and/or hazard lights - Troubleshooting Hazard lighting circuit Problem Possible Cause Correction Hazard Signal Lights will Blown fuse hazard, 15 A hazard signal Inspect fuse and replace as necessary. not illuminate or flash fuse.
  • Page 692 Electrical systems - External lighting Problem Possible Cause Correction 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. Instrument panel turn Indicator bulb burnt out. Inspect bulb and replace as necessary.
  • Page 693 Index Electrical systems - 55 External lighting - 404 External lighting - Troubleshooting Lighting circuit ......... . Headlight - Replace .
  • 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 Electrical systems - External lighting switches and relays 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 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 ............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 Contents Electrical systems - 55 Warning indicators, alarms, and instruments - 408 FUNCTIONAL DATA Warning indicators, alarms, and instruments Overview ................. . 3 Instrument cluster Overview .
  • Page 700 Electrical systems - Warning indicators, alarms, and instruments Warning indicators, alarms, and instruments - Overview GNIL14TR00512AA Turn signal switch Turn signal switch (1) indicates turn signals and should be moved to the right to operate right turn indicator light and left to operate left turn indicator light.
  • Page 701 Electrical systems - Warning indicators, alarms, and instruments Horn Button Press the horn button (7) for warning arrival Head Light Switch Positions The head light switch (8) consists of four positions, Position (1) - Off Position (2) - Parking lights on. Position (3) - Head lamp low beam.
  • Page 702 Electrical systems - Warning indicators, alarms, and instruments Instrument cluster - Overview GNIL14TR00509FA The indicator lights on the control panel inform you of the operational condition of the machine. Some of these indicate faults arising during operation. An indicator light coming on may be followed by a continuous or intermittent buzzer. Depending on the severity of the trouble, the alarm will sound.
  • Page 703 Electrical systems - Warning indicators, alarms, and instruments Indicator lamp (amber) This indicator light comes on and the display shows a warning symbol (30). The light blinks for 4 seconds, after which the symbol on the display disappears and the indicator light stays on steady.
  • Page 704 Electrical systems - Warning indicators, alarms, and instruments Work lights (amber) This warning light illuminates when the work lights are switched on. Information Display The display shows information on the operational condition of the machine and highlights any trouble in the form of symbols or error codes. Rev counter/ Techometer The rev counter (1) indicates the engine rpm.
  • Page 705 Electrical systems - Warning indicators, alarms, and instruments Central display The central liquid crystal display provides the operator with a range of information • Front or rear power take−off speed Front or rear lift position Slip Data displayed by pressing and releasing the button ENTER (A) •...
  • Page 706 Electrical systems - Warning indicators, alarms, and instruments Instrument cluster - Remove 1. Lift the front hood. 2. Disconnect battery terminals. NOTE: Always disconnect the negative cable (1) first. GNIL14TR00784AA 3. Remove the steering wheel cover (1). GNIL14TR00512AA 4. Loosen the steering wheel securing nut. GNIL14TR00846AA 5.
  • Page 707 Electrical systems - Warning indicators, alarms, and instruments 6. Disconnect the wiring connection (1) near the steering column. GNIL14TR00711AA 7. Loosen the bolt (1) and remove the shuttle lever. GNIL14TR00705AA 8. Remove the hand throttle knob. GNIL14TR00706AA 9. Unscrew all the screws of instrument panel. GNIL14TR00707AA 47866583_ 02/12/2015 55.10 [55.408] / 10...
  • Page 708 Electrical systems - Warning indicators, 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 47866583_ 02/12/2015 55.10 [55.408] / 11...
  • Page 709 Electrical systems - Warning indicators, alarms, and instruments Instrument cluster - Install 1. Connect wiring coupler to horn switch. GNIL14TR00772AA 2. Connect wiring coupler to head light switch. GNIL14TR00773AA 3. Connect wiring coupler to indicator switch. GNIL14TR00774AA 4. Connect wiring coupler to programming arrow switch. GNIL14TR00775AA 47866583_ 02/12/2015 55.10 [55.408] / 12...
  • Page 710 Electrical systems - Warning indicators, alarms, and instruments 5. Connect wiring coupler to home programming switch. GNIL14TR00776AA 6. Connect wiring coupler to Hi-Lo beam switch. GNIL14TR00777AA 7. Connect wiring coupler to hazard warning switch. GNIL14TR00778AA 8. Tighten all the screws (1) of instrument panel. GNIL14TR00707AA 47866583_ 02/12/2015 55.10 [55.408] / 13...
  • Page 711 Electrical systems - Warning indicators, alarms, and instruments 9. Fit the hand throttle knob. GNIL14TR00706AA 10. Fit the shuttle lever and tighten the bolt (1). GNIL14TR00705AA 11. Connect the wiring coupler (1) near the steering col- umn. GNIL14TR00711AA 12. Install the steering wheel and cover (1). GNIL14TR00512AA 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 47866583_ 02/12/2015 55.10 [55.408] / 15...
  • Page 713 Electrical systems - Warning indicators, alarms, and instruments Instrument cluster - Troubleshooting Problem Possible Cause Correction Warning lights and Blown #6 15 A fuse. Replace fuse. gauges inoperative Gauges erratic or Faulty ground circuit. Check ground connections for proper con- inoperative tact.
  • Page 714 Index Electrical systems - 55 Warning indicators, alarms, and instruments - 408 Instrument cluster - Install ............. . . Instrument cluster - Overview .
  • 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 .
  • Page 718 Electrical systems - Cab controls Joystick and Electric Hydraulic (EH) control - Remove 1. 1. Loosen the locknut on joystick cable. 2. Loosen the set screws on the connectors of joystick cable. 3. Slide the connector on the joystick cable. GNIL14TR00764AA 2.
  • 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 47866583_ 02/12/2015 55.11 [55.512] / 4...
  • Page 720 Electrical systems - Cab controls Joystick and Electric Hydraulic (EH) control - Install 1. Install the joystick on the mounting bracket and tighten the bolts (1). Connect the electrical coupling. GNIL14TR00787AA 2. Fit the cover (1) of the joystick and tighten the screws (2).
  • Page 721 Index Electrical systems - 55 Cab controls - 512 Joystick and Electric Hydraulic (EH) control - Install ........Joystick and Electric Hydraulic (EH) control - Remove .
  • 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 Contents Electrical systems - 55 FAULT CODES - DTC DIAGNOSTIC DTC 11C-02-Water in fuel sensor or sensor circuit failure [ECU] ........8 DTC 11C-03-Water in fuel detected or water in fuel circuit failure [ECU] .
  • Page 724 DTC 161-02-Short circuit error of injector in cylinder 1 [ECU] ........58 DTC 161-03-Short circuit of low side to high source of injector in cylinder 1 [ECU] .
  • Page 725 DTC 1DA-12-ECU internal failure - Fuel calibration [ECU] ........121 DTC 1E1-03-Starter relay high side driver circuit shorted to battery [ECU] .
  • Page 726 DTC 2D3-12-ECU internal failure - Software resets in DSM 1 [ECU] ......180 DTC 2D4-04-ECU internal failure - ROM error [ECU] .
  • Page 727 DTC 4E3-04-Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off [ECU] ............238 DTC 4E3-12-Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor [ECU] .
  • Page 728 DTC 72C-03-Glow plug 2 control circuit shorted to ground [ECU]....... . 294 DTC 78B-03-Throttle valve actuator position sensor voltage is higher than expected [ECU] .
  • Page 729 Electrical systems - FAULT CODES DTC 11C-02-Water in fuel sensor or sensor circuit failure Control Module : ECU NOTE: This fault code is for the Water in Fuel switch with black connector housing. Context: The water in fuel switch S-9102 provides a diagnostic self-test signal (less than 3.9 V for 2.5 s +/- 20%) at key-ON. If the Engine Control Unit (ECU) A-9000 does not sense the diagnostic self-test signal, this fault will occur and there will be no monitoring of water content in the fuel supply.
  • Page 730 Electrical systems - FAULT CODES From Value X-9125 pin 1 X-9102 pin K88 There should be continuity. X-9125 pin 2 Chassis ground There should be continuity. X-9125 pin 3 X-9102 pin K01 There should be continuity. Then use the multimeter to perform the following tests, on the vehicle (VE) harness from : From Value X-9125 pin 1...
  • Page 731 Electrical systems - FAULT CODES DTC 11C-03-Water in fuel detected or water in fuel circuit failure Control Module : ECU NOTE: This fault code is for the Water in Fuel switch with black connector housing. Context: The Engine Control Unit (ECU) A-9000 monitors the voltage output from the water in fuel switch S-9102 to determine if water is present in the fuel supply.
  • Page 732 Electrical systems - FAULT CODES Then use the multimeter to perform the following tests, on the vehicle (VE) harness from : From Value X-9125 pin 1 X-9125 pin 2 There should be no continuity X-9125 pin 1 X-9125 pin 3 There should be no continuity X-9125 pin 2 X-9125 pin 3...
  • Page 733 Electrical systems - FAULT CODES DTC 131-03-Engine coolant temperature sensor voltage is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature sensor B-9003 signal circuit. If the ECU A-9000 determines that voltage is higher than expected in the engine coolant temperature sensor B-9003 signal circuit, this fault will occur.
  • Page 734 Electrical systems - FAULT CODES From Value X-9006 pin 1 X-9001 pin A57 There should be continuity. X-9006 pin 2 X-9001 pin A58 There should be continuity. A. If there is continuity, leave the connector X-9001 disconnected and continue to Step 4. B.
  • Page 735 Electrical systems - FAULT CODES DTC 131-04-Engine coolant temperature sensor voltage is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature sensor B-9003 signal circuit. If the ECU A-9000 determines that voltage is lower than expected in the engine coolant temperature sensor B-9003 signal circuit, this fault will occur.
  • Page 736 Electrical systems - FAULT CODES 4. 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. 5.
  • Page 737 Electrical systems - FAULT CODES DTC 133-03-Intake manifold temperature sensor voltage is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold temperature sensor B-9001 signal circuit. If the ECU A-9000 determines that the intake manifold temperature sensor B-9001 signal circuit voltage is greater than 4.94 V, this fault will occur.
  • Page 738 Electrical systems - FAULT CODES From Value X-9003 pin 2 X-9001 pin A55 There should be continuity. X-9003 pin 3 X-9001 pin A10 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A.
  • Page 739 Electrical systems - FAULT CODES DTC 133-04-Intake manifold temperature sensor voltage is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold temperature sensor B-9001 signal circuit. If the ECU A-9000 determines that the intake manifold temperature sensor B-9001 signal circuit voltage is less than 266.40 mV, this fault will occur.
  • Page 740 Electrical systems - FAULT CODES 4. 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. 5.
  • Page 741 Electrical systems - FAULT CODES DTC 134-00-Intake manifold pressure sensor drifted high Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake manifold pressure sensor B-9001. Boost pressure is compared to environmental pressure by the ECU A-9000. If the ECU A-9000 determines that the difference between measured boost pressure and environmental pressure is greater than 0.1 bar (1.5 psi), this fault will occur.
  • Page 742 Electrical systems - FAULT CODES DTC 134-01-Intake manifold pressure sensor drifted low Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure. Boost pressure is compared to environmental pres- sure by the ECU A-9000. If the ECU A-9000 determines that the boost pressure is less than environmental pressure by 0.1 bar (1.5 psi), this fault will occur.
  • Page 743 Electrical systems - FAULT CODES DTC 134-03-Intake manifold pressure sensor voltage is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that the intake manifold pressure sensor B-9001 signal circuit voltage is greater than 4.92 V, this fault will occur.
  • Page 744 Electrical systems - FAULT CODES From Value X-9003 pin 4 X-9001 pin A40 There should be continuity. X-9003 pin 3 X-9001 pin A10 There should be continuity. NOTE: Wiggle the harness during the check to promote an intermittent electrical connection. A.
  • Page 745 Electrical systems - FAULT CODES DTC 134-04-Intake manifold pressure sensor voltage is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that the intake manifold pressure sensor B-9001 signal circuit voltage is less than 202.80 mV, this fault will occur.
  • Page 746 Electrical systems - FAULT CODES 4. 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.
  • Page 747 Electrical systems - FAULT CODES DTC 135-03-Fuel temperature sensor voltage is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the ECU A-9000 detects a voltage greater than 4.93 V in the signal circuit, this fault will occur. If this fault is not inhibited by another fault, the ECU A-9000 will freeze the fuel temperature value to 39.96 °C (103.93 °F).
  • Page 748 Electrical systems - FAULT CODES From Value X-9005 pin 1 There should be less than 5.5 V. Chassis ground A. If the specified values are measured, leave connector X-9005 disconnected and continue to Step 4. B. If the specified values are not measured, there is a short to battery or switched battery in the fuel temperature sensor B-9002 wiring.
  • Page 749 Electrical systems - FAULT CODES DTC 135-04-Fuel temperature sensor voltage is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel temperature sensor B-9002 signal circuit voltage. If the ECU A-9000 detects a voltage less than 198.00 mV in the signal circuit, this fault will occur. If this fault is not inhibited by another fault, the ECU A-9000 will freeze the fuel temperature value to 39.96 °C (103.93 °F).
  • Page 750 Electrical systems - FAULT CODES 4. Check the fuel temperature sensor B-9002 engine harness (EN) wiring for a short to ground condition. Disconnect the engine harness (EN) from the ECU A-9000 at connector X-9001. With the key in the OFF position use the a multimeter to perform the following continuity checks for a short to ground condition on the engine harness (EN) side : From Value...
  • Page 751 Electrical systems - FAULT CODES DTC 136-03-Fuel rail pressure sensor voltage is higher than expected Control Module : ECU NOTE: If the rail pressure 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.
  • Page 752 Electrical systems - FAULT CODES From Value X-9026 pin 2 X-9001 pin A41 There should be continuity. X-9026 pin 3 X-9001 pin A11 There should be continuity. A. If there is no continuity, there is an open circuit in the rail pressure sensor B-9004 engine harness (EN) wiring. Locate and repair the broken conductor.
  • Page 753 Electrical systems - FAULT CODES DTC 136-04-Fuel rail pressure sensor voltage is lower than expected Control Module : ECU NOTE: If the rail pressure 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.
  • Page 754 Electrical systems - FAULT CODES 4. 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. 5.
  • Page 755 Electrical systems - FAULT CODES DTC 137-02-Fuel pressure relief valve reached maximum allowed opening count Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 756 Electrical systems - FAULT CODES DTC 137-03-Fuel pressure relief valve is open Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 757 Electrical systems - FAULT CODES DTC 137-04-Fuel pressure relief valve is forced to open, perform pressure increase Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service.
  • Page 758 Electrical systems - FAULT CODES DTC 137-12-Averaged rail pressure is outside the expected tolerance range Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 759 Electrical systems - FAULT CODES DTC 141-02-Crankshaft speed sensor values are not plausible Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the crankshaft position sensor B-9007 characteristics for angle, speed determination, signal plausibility, and quality. If the ECU A-9000 determines that there are no crankshaft posi- tion signals detected for at least 4 engine revolutions, this fault will occur.
  • Page 760 Electrical systems - FAULT CODES From Value X-9039 pin 2 There should be between 2.4 - 2.6 V. Chassis ground X-9039 pin 1 Chassis ground There should be between 2.4 - 2.6 V. A. If there is between 2.4 - 2.6 V, leave connector X-9039 disconnected and continue to Step 6. B.
  • Page 761 Electrical systems - FAULT CODES DTC 141-04-Crankshaft speed sensor pattern is not plausible Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the crankshaft position sensor B-9007 characteristics for angle, speed determination, signal plausibility, and quality. If the ECU A-9000 detects greater than 80 crankshaft position signal plausibility errors, this fault will occur.
  • Page 762 Electrical systems - FAULT CODES 4. Check the crankshaft position sensor B-9007 engine harness (EN) wiring for an open circuit. 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 checks for an open circuit on the engine harness (EN) side : From Value...
  • Page 763 Electrical systems - FAULT CODES DTC 143-02-Camshaft speed sensor values are not plausible Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the camshaft position sensor B-9017 characteristics for angle, speed determination, signal plausibility, and quality. If the ECU A-9000 determines that no camshaft edge is detected for at least four crankshaft revolutions, this fault will occur.
  • Page 764 Electrical systems - FAULT CODES B. If there is no continuity, there is an open circuit in the camshaft position sensor B-9017 wiring. Locate and repair the broken conductor. 4. Replace the camshaft position sensor B-9017. Use the Electronic Service Tool (EST) to verify the status of this fault, DTC 143-Min - Camshaft sensor failure. A.
  • Page 765 Electrical systems - FAULT CODES DTC 143-04-Camshaft speed sensor pattern is not plausible Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the camshaft position sensor B-9017 characteristics for angle, speed determination, signal plausibility, and quality. If the ECU A-9000 determines that the camshaft signal does not match the expected pattern (edge, distance, level) or not all expected camshaft edges are detected during an engine revo- lution, this fault will occur.
  • Page 766 Electrical systems - FAULT CODES From Value X-9008 pin 2 There should be no continuity. Chassis ground X-9008 pin 2 X-9008 pin 1 There should be no continuity. X-9008 pin 2 X-9008 pin 3 There should be no continuity. X-9001 pin A28 All pins in connector X-9001 There should be no continuity.
  • Page 767 Electrical systems - FAULT CODES DTC 144-03-Compared camshaft and crankshaft speed sensor values are not plausible Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the camshaft position sensor B-9017 and the crankshaft position sensor B-9007 characteristics for angle, speed determination, signal plausibility, and quality. If the ECU A-9000 de- termines that the offset between the crankshaft signal and the expected camshaft first edge is less or greater than 10.00 °...
  • Page 768 Electrical systems - FAULT CODES DTC 151-03-Fuel rail pressure has exceeded maximum positive deviation limits Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 769 Electrical systems - FAULT CODES DTC 153-03-Fuel rail pressure has exceeded maximum negative deviation limits Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 770 Electrical systems - FAULT CODES Use a multimeter to perform the following resistance check: From Value X-9007 pin 1 X-9007 pin 2 There should be between 2.8 - 3.2 Ω. A. If the value is in the specified range, see Fuel injection system - Troubleshooting (10.218) to diagnose the fuel injection system.
  • Page 771 Electrical systems - FAULT CODES DTC 154-03-Fuel rail pressure has dropped below the minimum limit Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 772 Electrical systems - FAULT CODES DTC 155-03-Fuel rail pressure has exceeded maximum limit Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 773 Electrical systems - FAULT CODES Use a multimeter to perform the following resistance check: From Value X-9007 pin 1 X-9007 pin 2 There should be between 2.8 - 3.2 Ω (2.8 - 3.2 Ω). A. If the value is in the specified range, see Fuel injection system - Troubleshooting (10.218) to diagnose the fuel injection system.
  • Page 774 Electrical systems - FAULT CODES DTC 157-03-High pressure pump fuel delivery quantity in over run exceeds a maximum threshold Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the high pressure fuel system for leakage during overrun. If the ECU A-9000 detects that the high pressure pump quantity in overrun exceeds the expected threshold, this fault will occur.
  • Page 775 Electrical systems - FAULT CODES DTC 158-03-Fuel pump pressure has exceeded desired pressure limits Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 776 Electrical systems - FAULT CODES DTC 159-02-Fuel metering unit has an open load error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects an open load error in the fuel metering unit Y-9000 signal circuit, this fault will occur. Cause: There is open load detected in the fuel metering unit Y-9000 signal circuit.
  • Page 777 Electrical systems - FAULT CODES 4. 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.
  • Page 778 Electrical systems - FAULT CODES DTC 15D-03-PMCat Inducement less severe derating level Control Module : ECU Context: The Engine Control 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.
  • Page 779 Electrical systems - FAULT CODES DTC 161-02-Short circuit error of injector in cylinder 1 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 1 Y-9001 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit in the fuel injector number 1 Y-9001 circuit.
  • Page 780 Electrical systems - FAULT CODES B. If there is voltage, there is a short to battery or switched battery in the fuel injector number 1 Y-9001 wiring in the engine harness (EN). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
  • Page 781 Electrical systems - FAULT CODES Wiring harnesses - Electrical schematic sheet 01 – Power distribution and glow plugs (engine schematics) (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 –...
  • Page 782 Electrical systems - FAULT CODES DTC 161-03-Short circuit of low side to high source of injector in cylinder 1 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 1 Y-9001 circuit, this fault will occur.
  • Page 783 Electrical systems - FAULT CODES With the key in the OFF position, use a multimeter to perform the following continuity check on engine harness (EN) side : From Value X-9001 pin A16 All pins in connector X-9001 There should be no continuity X-9001 pin A32 All pins in connector X-9001 There should be no continuity...
  • Page 784 Electrical systems - FAULT CODES DTC 162-02-Short circuit error of injector in cylinder 2 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 2 Y-9002 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit in the fuel injector number 2 Y-9002 circuit.
  • Page 785 Electrical systems - FAULT CODES B. If there is voltage, there is a short to battery or switched battery in the fuel injector number 2 Y-9002 wiring in the engine harness (EN). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
  • Page 786 Electrical systems - FAULT CODES Wiring harnesses - Electrical schematic sheet 01 – Power distribution and glow plugs (engine schematics) (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 –...
  • Page 787 Electrical systems - FAULT CODES DTC 162-03-Short circuit of low side to high source of injector in cylinder 2 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 2 Y-9002 circuit, this fault will occur.
  • Page 788 Electrical systems - FAULT CODES With the key in the OFF position, use a multimeter to perform the following continuity check on engine harness (EN) side : From Value X-9001 pin A17 All pins in connector X-9001 There should be no continuity X-9001 pin A48 All pins in connector X-9001 There should be no continuity...
  • Page 789 Electrical systems - FAULT CODES DTC 163-02-Short circuit error of injector in cylinder 3 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 3 Y-9003 circuit, this fault will occur. Cause: The ECU A-9000 has detected a short circuit in the fuel injector number 3 Y-9003 circuit.
  • Page 790 Electrical systems - FAULT CODES B. If there is voltage, there is a short to battery or switched battery in the fuel injector number 3 Y-9003 wiring in the engine harness (EN). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
  • Page 791 Electrical systems - FAULT CODES Wiring harnesses - Electrical schematic sheet 01 – Power distribution and glow plugs (engine schematics) (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 –...
  • Page 792 Electrical systems - FAULT CODES DTC 163-03-Short circuit of low side to high source of injector in cylinder 3 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector power stages for a short circuit condition. If the ECU A-9000 detects a short circuit condition in the injector number 3 Y-9003 circuit, this fault will occur.
  • Page 793 Electrical systems - FAULT CODES Disconnect the vehicle harness (VE) from the ECU A-9000 at connector X-9121. With the key in the OFF position, use a multimeter to perform the following continuity check on vehicle harness (VE) side : From Value X-9139 pin D X-9139 pin C...
  • Page 794 Electrical systems - FAULT CODES DTC 167-02-Open load error of injector in cylinder 1 Control Module : ECU NOTE: If a fuel injector is replaced, it is necessary to program the new injector IMA code using the Electronic Service Tool (EST). The IMA code may be under the paint on the fuel injector. For more information regarding programming IMA codes, see Fuel injectors - Configure - IMA codes (10.218).
  • Page 795 Electrical systems - FAULT CODES 4. 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.
  • Page 796 Electrical systems - FAULT CODES DTC 168-02-Open load error of injector in cylinder 2 Control Module : ECU NOTE: If a fuel injector is replaced, it is necessary to program the new injector IMA code using the Electronic Service Tool (EST). The IMA code may be under the paint on the fuel injector. For more information regarding programming IMA codes, see Fuel injectors - Configure - IMA codes (10.218).
  • Page 797 Electrical systems - FAULT CODES 4. 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.
  • Page 798 Electrical systems - FAULT CODES DTC 169-02-Open load error of injector in cylinder 3 Control Module : ECU NOTE: If a fuel injector is replaced, it is necessary to program the new injector IMA code using the Electronic Service Tool (EST). The IMA code may be under the paint on the fuel injector. For more information regarding programming IMA codes, see Fuel injectors - Configure - IMA codes (10.218).
  • Page 799 Electrical systems - FAULT CODES 4. 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.
  • Page 800 Electrical systems - FAULT CODES DTC 171-03-Injection bank 1 short circuit failure (all injectors of the same bank can be affected) Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector harness for a short circuit condition. If the ECU A-9000 detects a short circuit pattern in the bank 1 fuel injectors, this fault will occur.
  • Page 801 Electrical systems - FAULT CODES DTC 173-03-Injection bank 2 short circuit failure (all injectors of the same bank can be affected) Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel injector harness for a short circuit condition. If the ECU A-9000 detects a short circuit pattern in the fuel injector harness of both bank 2 fuel injections, this fault will occur.
  • Page 802 Electrical systems - FAULT CODES 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.
  • Page 803 Electrical systems - FAULT CODES DTC 17C-12-ECU internal failure - Injector CY33x component Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors diagnostic checks on the fuel injection power stages. This diagnostic procedure uses pattern 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.
  • Page 804 Electrical systems - FAULT CODES DTC 17E-02-Number of desired injections exceeds threshold Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the requested number of fuel injections. If the ECU A-9000 deter- mines that the number of requested injections is greater than the current capability of the fuel injection system, this fault will occur, Cause: The ECU A-9000 has determined that the number of requested fuel injections has exceeded the current capability of...
  • Page 805 Electrical systems - FAULT CODES DTC 17E-03-Exceeded the number of injections for a given engine speed Control Module : ECU Context: The ECU A-9000 monitors the requested number of fuel injections and the current capability of the injection system fulfilling that request. If the ECU A-9000 determines that the requested number of injections is greater than the current capability of the fuel injection system for the current engine speed, this fault will occur.
  • Page 806 Electrical systems - FAULT CODES DTC 17E - 04-Injection control : Number of injections is limited by system Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the requested number of fuel injections and the current capability of the fuel injection system to fulfill that request.
  • Page 807 Electrical systems - FAULT CODES DTC 17E-12-Number of injections is limited by quantity balance of high pressure pump Control Module : ECU Context: The ECU A-9000 monitors the requested number of fuel injections and the current capability of the fuel injection sys- tem to fulfill that request.
  • Page 808 Electrical systems - FAULT CODES DTC 17F-12-Missing adjustment value programming for injector in cylinder 1 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 uses an IMA code to correct fuel trim for each fuel injector equipped with the engine at every key ON.
  • Page 809 Electrical systems - FAULT CODES DTC 18F-02-Lambda sensor heater power stage open circuit Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 810 Electrical systems - FAULT CODES A. If there is no continuity, there is an open circuit in the Lambda sensor B-9123 low side driver wiring between connector X-9123 pin 3 and connector X-9102 pin K07. Use the appropriate service manual, if necessary, to locate and repair the broken conductor.
  • Page 811 Electrical systems - FAULT CODES DTC 18F-03-Lambda sensor heater power stage short circuit to battery Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 812 Electrical systems - FAULT CODES A. If there is continuity, there is a short to a voltage source condition in the vehicle harness (VE). Use the appro- priate service manual, if necessary, to locate and repair the shorted conductors. B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4.
  • Page 813 Electrical systems - FAULT CODES DTC 18F-04-Lambda sensor heater power stage short circuit to ground Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 814 Electrical systems - FAULT CODES B. If there is no continuity, the ECU A-9000 connector X-9102 is damaged or the ECU A-9000 has failed. Locate and repair the damage or replace the ECU A-9000. 4. Replace the Lambda sensor B-9123. Use the EST, see Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989) if necessary, to perform the Replacement of the Lambda Sensor - Reset ECU Data.
  • Page 815 Electrical systems - FAULT CODES DTC 18F-04-Lambda sensor heater power stage short circuit to ground Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 816 Electrical systems - FAULT CODES B. If this fault has not been resolved, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires.
  • Page 817 Electrical systems - FAULT CODES DTC 199-02-Turbocharger boost pressure is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that 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).
  • Page 818 Electrical systems - FAULT CODES DTC 199-02-Turbocharger boost pressure is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that 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).
  • Page 819 Electrical systems - FAULT CODES DTC 1B1-03-CAN A Bus off failure Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a func- tion of the ECU A-9000.
  • Page 820 Electrical systems - FAULT CODES 4. Determine the condition of the ECU A-9000 CAN circuit. With the key switch in the OFF position, use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side: From Value X-9102 pin K24...
  • Page 821 Electrical systems - FAULT CODES DTC 1B1-04-CAN A Bus off passive failure Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a func- tion of the ECU A-9000.
  • Page 822 Electrical systems - FAULT CODES 4. Determine the condition of the ECU A-9000 CAN circuit. With the key switch in the “OFF” position, use a multimeter to measure the resistance of the CAN connection on the vehicle (VE) harness side: From Value X-9122 pin K24...
  • Page 823 Electrical systems - FAULT CODES DTC 1B5-02-CAN communication error between vehicle controller to ECU Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two or more separate Controller Area Networks (CAN). Proper configuration and monitoring of these twisted pair configured networks is also a function of the ECU A-9000.
  • Page 824 Electrical systems - FAULT CODES B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000. 4.
  • Page 825 Electrical systems - FAULT CODES DTC 1B7-02-CAN transmit error - EEC1 message (Electronic Engine Control 1 message - Torque, accelerator pedal, engine speed, and other signals) Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN).
  • Page 826 Electrical systems - FAULT CODES B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000. 4.
  • Page 827 Electrical systems - FAULT CODES DTC 1C6-03-CAN communication failure between vehicle controller and ECU controller - TSC1_PE message Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN).
  • Page 828 Electrical systems - FAULT CODES B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000. 4.
  • Page 829 Electrical systems - FAULT CODES DTC 1C8-03-CAN communication failure between vehicle controller and ECU controller - TSC1_VE message Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN).
  • Page 830 Electrical systems - FAULT CODES B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000. 4.
  • Page 831 Electrical systems - FAULT CODES DTC 1D1-03-ECU internal failure Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs a diagnostic check of the sensor supplies by monitoring the sensor supplies communication. If the ECU A-9000 detects a communication error during this diagnostic check, this fault will occur.
  • Page 832 Electrical systems - FAULT CODES DTC 1D2-02-ECU internal failure - EEPROM write error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU A-9000 checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found.
  • Page 833 Electrical systems - FAULT CODES DTC 1D2-03-ECU internal failure - EEPROM erase error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 has a functionality for reading and erasing values to 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.
  • Page 834 Electrical systems - FAULT CODES DTC 1D2-04-ECU internal failure - EEPROM read error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU A-9000 checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found.
  • Page 835 Electrical systems - FAULT CODES DTC 1D2-12-ECU internal failure - EEPROM write/read error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 has detected an error during the last EEPROM write operation. The hardware encapsulation of the ECU A-9000 checks each data block of the EEPROM and sets a status flag depending on if an error is found or not found.
  • Page 836 Electrical systems - FAULT CODES DTC 1D3-12-ECU internal failure - Software resets in DSM 0 Control Module : ECU Context: If this fault is active, the Engine Control Unit (ECU) A-9000 has detected an error that has led to a software reset. Solution: 1.
  • Page 837 Electrical systems - FAULT CODES DTC 1D4-12-ECU internal failure - Query/response communication errors Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the communication between 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.
  • Page 838 Electrical systems - FAULT CODES DTC 1D8-12-ECU internal failure - SPI communication error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the communication between 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.
  • Page 839 Electrical systems - FAULT CODES DTC 1D9-02-ECU internal failure - ADC test Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (ADC) plausibility by performing a fixed input voltage test. If the voltage during the test is out of range, this fault will occur. Solution: 1.
  • Page 840 Electrical systems - FAULT CODES DTC 1D9-03-ECU internal failure - Voltage ratio in ADC monitoring Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (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.
  • Page 841 Electrical systems - FAULT CODES DTC 1D9-12-ECU internal failure - NTP error in ADC monitoring Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the Analog Digital Converter (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.
  • Page 842 Electrical systems - FAULT CODES DTC 1DA-12-ECU internal failure - Fuel calibration Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 checks the map for the conversion from fuel quantity to torque for consistency. If there is an error during this conversion check, this fault will occur. Solution: 1.
  • Page 843 Electrical systems - FAULT CODES DTC 1E1-03-Starter relay high side driver circuit shorted to battery Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects a short circuit to battery in the high side driver circuit, this fault will occur.
  • Page 844 Electrical systems - FAULT CODES 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 perform the following continuity check for short circuit on the vehicle harness (VE) side : From Value X-9102 pin K53...
  • Page 845 Electrical systems - FAULT CODES DTC 1E1-04-Starter relay high side driver circuit shorted to ground Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects a short circuit to ground in the high side driver circuit, this fault will occur.
  • Page 846 Electrical systems - FAULT CODES From Value X-9102 pin K53 All pins in connector X-9102 There should be no continuity. A. If there is continuity, there is a short to ground in the starter control relay K-9104 wiring in the vehicle harness (VE).
  • Page 847 Electrical systems - FAULT CODES DTC 1E3-03-Fuel injection requested during overrun Control Module : ECU Context: The Engine Control Unit (ECU) A-9000, during after run, monitors fuel injector actuation time by calculating the de- manded 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.
  • Page 848 Electrical systems - FAULT CODES DTC 1E4-03-ECU internal failure - Calculated engine speed Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors engine speed in multiple 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.
  • Page 849 Electrical systems - FAULT CODES DTC 1E6-12-ECU 5 volt sensor supply 1 out of range Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 provides three independent five volt sensor supplies. The ECU A-9000 mon- itors each sensor supply voltage to ensure they operate within a given range. If the ECU A-9000 determines that the voltage for sensor supply 1 is out of range, this fault will occur.
  • Page 850 Electrical systems - FAULT CODES Physical condition X-9001 pin A09 The pin and connector should be free of corrosion or damage. X-9001 pin A10 The pin and connector should be free of corrosion or damage. X-9001 pin A11 The pin and connector should be free of corrosion or damage.
  • Page 851 Electrical systems - FAULT CODES With the key in the OFF position, use a multimeter to perform the following continuity checks on the engine harness (EN) side : From Value X-9011 pin 1 Chassis ground There should be no continuity. X-9011 pin 1 X-9011 pin 3 There should be no continuity.
  • Page 852 Electrical systems - FAULT CODES With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From Value X-9001 pin A11 All pins in connector X-9001. There should be no continuity. A.
  • Page 853 Electrical systems - FAULT CODES DTC 1E7-03-ECU 5 volt sensor supply 2 out of range Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 provides three independent five volt sensor supplies. The ECU A-9000 mon- itors each sensor supply voltage to ensure they operate within a given range. If the ECU A-9000 determines that the voltage for sensor supply 2 is out of range, this fault will occur.
  • Page 854 Electrical systems - FAULT CODES 4. Check the following pins listed below on the ECU A-9000 and in connector X-9102. Physical condition X-9102 pin K12 The pin and connector should be free of corrosion or damage. X-9102 pin K13 The pin and connector should be free of corrosion or damage.
  • Page 855 Electrical systems - FAULT CODES DTC 1E8-03-ECU 5 volt sensor supply 3 out of range Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 provides three independent five volt sensor supplies. The ECU A-9000 mon- itors each sensor supply voltage to ensure they operate within a given range. If the ECU A-9000 determines that the voltage for sensor supply 3 is out of range, this fault will occur.
  • Page 856 Electrical systems - FAULT CODES 4. Disconnect the engine harness (EN) from the ECU A-9000 at connector X-9001. Check the following pins listed below on the ECU A-9000 and in connectors X-9001 and X-9102. Physical condition X-9102 pin K17 The pin and connector should be free of corrosion or damage.
  • Page 857 Electrical systems - FAULT CODES DTC 1EB-03-ECU internal failure - Ambient pressure sensor voltage is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors atmospheric pressure. The ECU A-9000 performs a signal range check of the atmospheric pressure sensor value. If the ECU A-9000 determines that the value is too high, this fault will occur.
  • Page 858 Electrical systems - FAULT CODES DTC 1EB-04-ECU internal failure - Ambient pressure sensor voltage is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors atmospheric pressure. The ECU A-9000 performs a signal range check of the atmospheric pressure sensor value. If the ECU A-9000 determines that the value is too low, this fault will occur.
  • Page 859 Electrical systems - FAULT CODES DTC 1F7-00-PMCat inlet temperature sensor physical range check high Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter (PM) catalytic converter inlet temperature sen- sor B-9127. If the ECU A-9000 detects a temperature greater than 1000 °C (1832 °F) from the PM catalytic converter inlet temperature sensor B-9127, this fault will occur.
  • Page 860 Electrical systems - FAULT CODES From Value X-9127 pin 1 There should be less than 5.5 V Chassis ground A. If the specified values are not measured, there is a short to battery in the PM catalytic converter inlet tempera- ture sensor B-9127 wiring.
  • Page 861 Electrical systems - FAULT CODES DTC 1F7-03-PMCat inlet temperature sensor voltage is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter (PM) catalytic converter inlet temperature sensor B-9127. If the ECU A-9000 detects a voltage greater than 3.59 V in the PM catalytic converter inlet temperature sensor B-9127 signal circuit, this fault will occur.
  • Page 862 Electrical systems - FAULT CODES A. If the specified values are not measured, there is a short to battery in the PM catalytic converter inlet tempera- ture sensor B-9127 wiring. Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
  • Page 863 Electrical systems - FAULT CODES DTC 1F7-04-PMCat inlet temperature sensor voltage is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the Particulate Matter (PM) catalytic converter inlet temperature sen- sor B-9127. If the ECU A-9000 detects a voltage less than 459.40 mV in the PM catalytic converter inlet temperature sensor B-9127 signal circuit, this fault will occur.
  • Page 864 Electrical systems - FAULT CODES B. If there is no continuity, leave the connectors disconnected and continue to Step 4. 4. Check the PM catalytic converter inlet temperature sensor B-9127 vehicle harness (VE) wiring for a short circuit condition. Disconnect the vehicle harness from the ECU A-9000 at connector X-9102. With the key in the OFF position, use a multimeter to perform the following continuity check at the vehicle harness (VE) side of the connectors from : From...
  • Page 865 Electrical systems - FAULT CODES DTC 225-03-Main relay stuck error Control Module : ECU Context: The Engine Control Unit A-9000 controls the main relay K-9102. The main relay K-9102 is powered on by the ECU A-9000 to achieve after-run. The main relay K-9102 is powered off once after-run is completed. If the ECU A-9000 determines that the main relay K-9102 is “stuck”...
  • Page 866 Electrical systems - FAULT CODES From Value X-9102 pin K28 All pins in connector X-9102 There should be no continuity. A. If there is continuity, there is a short circuit in the main relay K-9102 wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the shorted conductor.
  • Page 867 Electrical systems - FAULT CODES DTC 225-03-Main relay stuck error Control Module : ECU Context: The Engine Control Unit A-9000 controls the main relay K-9102. The main relay K-9102 is powered on by the ECU A-9000 to achieve after-run. The main relay K-9102 is powered off once after-run is completed. If the ECU A-9000 determines that the main relay K-9102 has shut off before commanded, this fault will occur.
  • Page 868 Electrical systems - FAULT CODES B. If there is no voltage, leave the main relay K-9102 disconnected and continue to Step 4. 4. Check the main relay K-9102 vehicle harness (VE) wiring for a short to ground. With the key in the OFF position, use a multimeter to perform the following continuity check for a short to ground on the vehicle harness (VE) side : From Value...
  • Page 869 Electrical systems - FAULT CODES 8. Check the main relay K-9102 load-side wiring. With the key in the OFF position, use a multimeter to perform the following continuity checks on the vehicle harness (VE) side : From Value X-9129 pin 87 X-9102 pin K01 There should be continuity.
  • Page 870 Electrical systems - FAULT CODES DTC 226-03-Battery voltage is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the battery voltage. If the ECU A-9000 detects a voltage higher than expected, this fault will occur. Cause: The ECU A-9000 has detected a battery voltage of greater than 28.8 V.
  • Page 871 Electrical systems - FAULT CODES DTC 226-04-Battery voltage is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the battery voltage. If the ECU A-9000 detects a voltage lower than expected, this fault will occur. Cause: The ECU A-9000 has detected a battery voltage of less than 8.3 V.
  • Page 872 Electrical systems - FAULT CODES A. If there is less than approximately 12 V, continue to Step 5. B. If there is approximately 12 V, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 5. Check the ECU A-9000 voltage supply wiring for a short circuit to ground. With the key in the ON position, use a multimeter to perform the following voltage check on the vehicle harness (VE) side : From...
  • Page 873 Electrical systems - FAULT CODES DTC 236-03-Rail pressure sensor value is above maximum offset Control Module : ECU NOTE: If the rail pressure 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.
  • Page 874 Electrical systems - FAULT CODES DTC 236-03-Rail pressure sensor value is above maximum offset Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.
  • Page 875 Electrical systems - FAULT CODES DTC 236-04-Rail pressure sensor value is below minimum offset Control Module : ECU NOTE: If the rail pressure 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.
  • Page 876 Electrical systems - FAULT CODES DTC 237-04-Fuel pressure relief valve is forced to open, perform pressure shock Control Module : ECU Context: This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The Engine Control Unit (ECU) A-9000, if necessary, will set the engine into limp home mode.
  • Page 877 Electrical systems - FAULT CODES DTC 237-04-Fuel pressure relief valve is forced to open, perform pressure shock Control Module : ECU Context: This fault is intended for information purposes only. Other active faults may have caused this fault to occur. The Engine Control Unit (ECU) A-9000, if necessary, will set the engine into limp home mode.
  • Page 878 Electrical systems - FAULT CODES DTC 237-12-Quantity balance check if a successful PRV opening is ensured Control Module : ECU Context: This fault is intended for information purposes 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).
  • Page 879 Electrical systems - FAULT CODES DTC 237-12-Quantity balance check if a successful PRV opening is ensured Control Module : ECU Context: This fault is intended for information purposes 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).
  • Page 880 Electrical systems - FAULT CODES DTC 238-03-Oil pressure switch active with engine off Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the oil pressure switch S-9016 for proper operation. The oil pressure switch S-9016 changes from its off to on state between 0.6 - 0.9 bar (8.7 - 13.0 psi). If the oil pressure switch S-9016 does not return to its off state, once the engine is switched OFF, this fault will occur.
  • Page 881 Electrical systems - FAULT CODES 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.
  • Page 882 Electrical systems - FAULT CODES DTC 238-04-Low oil pressure Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the oil pressure switch S-9016 for proper operation. The oil pressure switch S-9016 changes from its off to on state between 0.6 - 0.9 bar (8.7 - 13.0 psi). If the oil pressure switch S-9016 does actuate once the engine has been running for 6.0 s at greater than 500.0 RPM, this fault will occur.
  • Page 883 Electrical systems - FAULT CODES B. If the oil pressure switch S-9016 did not change state, leave connector X-9016 disconnected and continue with Step 6. 4. Check the oil pressure switch S-9016 circuit for a short to ground condition. With the key switch in the OFF position, use a multimeter to check for continuity on the engine harness (EN) side : From Result X-9016 pin 1...
  • Page 884 Electrical systems - FAULT CODES DTC 256-03-Engine speed limitation via fuel injection cut off is active Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 will perform an injection cut-off to limit the engine speed to a controllable range, if needed.
  • Page 885 Electrical systems - FAULT CODES DTC 259-03-Fuel metering unit is shorted to battery voltage at the low side Control Module : ECU Context: The Engine Control Unit (ECU) monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects a short to a voltage source in the fuel metering unit Y-9000 low side driver circuit, this fault will occur.
  • Page 886 Electrical systems - FAULT CODES B. If there is no voltage, leave connector X-9007 disconnected and continue to Step 4. 4. Check the fuel metering unit Y-9000 low side driver engine harness (EN) wiring for a short circuit condition. 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 from the engine har- ness (EN) side : From...
  • Page 887 Electrical systems - FAULT CODES DTC 25A-03-Error in comparing energizing time to maximum value for injector in cylinder 1 Control Module : ECU Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection.
  • Page 888 Electrical systems - FAULT CODES DTC 25A-04-Error in comparing energizing time to minimum value for injector in cylinder 1 Control Module : ECU Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection.
  • Page 889 Electrical systems - FAULT CODES DTC 25D-03-PMCat Inducement most severe derating level Control Module : ECU Context: 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.
  • Page 890 Electrical systems - FAULT CODES DTC 26F-04-The minimum rail pressure value necessary to allow fuel injection has not been reached Control Module : ECU NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service.
  • Page 891 Electrical systems - FAULT CODES DTC 27F-12-Missing adjustment value programming for injector in cylinder 2 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 uses an IMA code to correct fuel trim for each fuel injector equipped with the engine at every key ON.
  • Page 892 Electrical systems - FAULT CODES DTC 299-04-Turbocharger boost pressure is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors boost pressure using the intake manifold pressure sensor B-9001. If the ECU A-9000 determines that boost pressure is lower than expected, this fault will occur. For more information regarding the troubleshooting of an under-boost condition, see Turbocharger - Troubleshooting (10.250).
  • Page 893 Electrical systems - FAULT CODES DTC 2B4-02-CAN communication failure between vehicle controller and ECU - BC2ECU2 message Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN). Proper configuration and monitoring of the two twisted pair configured networks is also a func- tion of the ECU A-9000.
  • Page 894 Electrical systems - FAULT CODES B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000. 4.
  • Page 895 Electrical systems - FAULT CODES DTC 2C6-02-CAN communication failure between vehicle controller and ECU controller - TSC1_PE message Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN).
  • Page 896 Electrical systems - FAULT CODES B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000. 4.
  • Page 897 Electrical systems - FAULT CODES DTC 2CC-00-Engine controller internal temperature out of range (High) Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor. If the ECU A-9000 determines that the temperature sensor value 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.
  • Page 898 Electrical systems - FAULT CODES DTC 2CC-01-Engine controller internal temperature out of range (Low) Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor. If the ECU A-9000 determines that the temperature sensor value 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.
  • Page 899 Electrical systems - FAULT CODES DTC 2CC-12-Engine controller internal temperature out of range (SPI Error - LM71) Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 has an internal temperature sensor. The ECU A-9000 monitors this sensor and if the ECU A-9000 determines 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.
  • Page 900 Electrical systems - FAULT CODES DTC 2D1-03-ECU internal failure - Error on R2S2 module Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 has detected an error on the R2S2 module (low-level chip driver for the power- stage chips). Solution: 1.
  • Page 901 Electrical systems - FAULT CODES DTC 2D3-12-ECU internal failure - Software resets in DSM 1 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 will perform a software reset if a software failure is detected. If this fault is active, a software failure has been reported and a software reset has occurred.
  • Page 902 Electrical systems - FAULT CODES DTC 2D4-04-ECU internal failure - ROM error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 runs a diagnostic fault check of the ROM memory. If any checksum errors in ROM-memory blocks are detected, this fault will occur. Solution: 1.
  • Page 903 Electrical systems - FAULT CODES DTC 2E1-02-Starter relay low side driver circuit open Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects an open circuit in the high side driver circuit, this fault will occur. Cause: The ECU A-9000 has detected an open circuit in the starter control relay K-9104 high side driver circuit.
  • Page 904 Electrical systems - FAULT CODES 4. 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.
  • Page 905 Electrical systems - FAULT CODES DTC 2E1-03-Starter relay low side driver circuit shorted to battery Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects a short circuit to battery in the low side driver circuit, this fault will occur.
  • Page 906 Electrical systems - FAULT CODES 4. Check the starter control relay K-9104 low side driver vehicle harness (VE) wiring for a short circuit. 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 perform the following continuity check on the vehicle harness (VE) side : From Value...
  • Page 907 Electrical systems - FAULT CODES DTC 2E1-04-Starter relay low side driver circuit shorted to ground Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects a short circuit to ground in the low side driver circuit, this fault will occur.
  • Page 908 Electrical systems - FAULT CODES B. If there is no continuity, check the ECU A-9000 for the appropriate software and re-flash, if necessary. 4. 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.
  • Page 909 Electrical systems - FAULT CODES DTC 2E1-12-Starter relay low side ECU driver circuit over temperature Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 controls the starter control relay K-9104 using a low side and high side driver. If the ECU A-9000 detects an over temperature/current condition in the high side driver circuit, this fault will occur.
  • Page 910 Electrical systems - FAULT CODES With the key in the OFF position, use a multimeter to perform the following voltage check for a short to a voltage source on the vehicle harness (VE) side : From Value X-9120 pin 86 Chassis ground There should be no voltage.
  • Page 911 Electrical systems - FAULT CODES DTC 32B-02-Glow plug control circuits open Control Module : ECU Context: For information regarding the functional operation of the glow plug control module Z-9101 see Glow plug system Glow plug control module - Overview – Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101.
  • Page 912 Electrical systems - FAULT CODES A. If there is continuity on all of the checks, continue to Step 4. B. If there is no continuity on one or more of the checks, there is an open circuit condition in the vehicle harness (VE) between the glow plug control module Z-9101 and the respective glow plug.
  • Page 913 Electrical systems - FAULT CODES DTC 32B-03-Glow plug control circuits shorted to battery Control Module : ECU Context: For information regarding the functional operation of the glow plug control module Z-9101 see Glow plug system Glow plug control module - Overview – Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101.
  • Page 914 Electrical systems - FAULT CODES 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.
  • Page 915 Electrical systems - FAULT CODES DTC 32B-04-Glow plug control circuits shorted to ground Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101.
  • Page 916 Electrical systems - FAULT CODES A. If there is continuity, there is a short to ground condition in the glow plug control circuit wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B.
  • Page 917 Electrical systems - FAULT CODES DTC 32B-12-Glow plug control circuits shorted Control Module : ECU Context: For information regarding the functional operation of the glow plug control module Z-9101 see Glow plug system Glow plug control module - Overview – Glow plug control module (55.202). The Engine Control Unit (ECU) A-9000 requests operation of the glow plug control module Z-9101 via a Pulse Width Modulated (PWM) control circuit and monitors the status of possible electrical defects via a diagnostic feedback signal from the glow plug control module Z-9101.
  • Page 918 Electrical systems - FAULT CODES A. If there is continuity, there is a short to ground condition in the glow plug control circuit wiring in the vehicle harness (VE). Use the appropriate service manual, if necessary, to locate and repair the grounded conductor. B.
  • Page 919 Electrical systems - FAULT CODES DTC 359-04-Fuel metering unit is shorted to ground at the low side Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 low side driver circuit. If the ECU A-9000 detects a short to ground in the fuel metering unit Y-9000 low side driver circuit, this fault will occur.
  • Page 920 Electrical systems - FAULT CODES 4. 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.
  • Page 921 Electrical systems - FAULT CODES DTC 35A-03-Error in comparing energizing time to maximum value for injector in cylinder 2 Control Module : ECU Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection.
  • Page 922 Electrical systems - FAULT CODES DTC 35A-04-Error in comparing energizing time to minimum value for injector in cylinder 2 Control Module : ECU Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection.
  • Page 923 Electrical systems - FAULT CODES DTC 35D-03-PMCat Inducement warning Control Module : ECU Context: 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.
  • Page 924 Electrical systems - FAULT CODES DTC 37F-12-Missing adjustment value programming for injector in cylinder 3 Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 uses an IMA code to correct fuel trim for each fuel injector equipped with the engine at every key ON.
  • Page 925 Electrical systems - FAULT CODES DTC 3C8-02-CAN communication failure between vehicle controller and ECU controller - TSC1_VE message Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 is capable of connecting to and communicating on two separate Controller Area Networks (CAN).
  • Page 926 Electrical systems - FAULT CODES B. If the voltage is not present for one or more of the checks, see the appropriate vehicle service manual and electrical schematics, if necessary, to locate and restore supply power to the ECU A-9000. 4.
  • Page 927 Electrical systems - FAULT CODES DTC 3D4-02-ECU internal failure - ECU shutdown test failure Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs a series of “shut-off path” tests which deactivates all power stages 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.
  • Page 928 Electrical systems - FAULT CODES DTC 3D4-03-ECU internal failure - Wrong set response time Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs a series of “shut-off path” tests which deactivates 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.
  • Page 929 Electrical systems - FAULT CODES DTC 3D4-04-ECU internal failure - SPI errors during MoCSOP execution Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs a series of “shut-off path” tests which deactivates 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.
  • Page 930 Electrical systems - FAULT CODES DTC 3D4-12-ECU internal failure - Loss of synchronization to MM from CPU Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs a shut-off path test of the fuel injection power stages. Every time the key is turned ON, this test is performed to verify the correct functioning of the shut-off procedure.
  • Page 931 Electrical systems - FAULT CODES DTC 3E3-00-ECU internal failure - Fuel injection energizing time is not plausible Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors fuel injector energizing 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.
  • Page 932 Electrical systems - FAULT CODES DTC 3E3-01-ECU internal failure - Fuel injection energizing phase is not plausible Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors fuel injector energizing 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.
  • Page 933 Electrical systems - FAULT CODES DTC 3E3-02-Fuel injection correction has exceeded a minimum limit Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 checks the plausibility of the Zero Fuel Quantity Calibration (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.
  • Page 934 Electrical systems - FAULT CODES DTC 3E3-03-ECU internal failure - Injection quantity correction Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 checks the plausibility of the Zero Fuel Quantity Calibration (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.
  • Page 935 Electrical systems - FAULT CODES DTC 3E3-04-ECU internal failure - Rail pressure plausibility Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors fuel pressure in the common rail. This monitoring is performed using two software levels 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.
  • Page 936 Electrical systems - FAULT CODES DTC 3E3-12-ECU internal failure - Torque request comparison Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs a diagnostic comparison of requested engine 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.
  • Page 937 Electrical systems - FAULT CODES DTC 3F6-03-DOC inlet temperature sensor voltage is higher than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the Diesel Oxidation Catalyst (DOC) inlet temperature sensor B-9127. If the ECU A-9000 detects a voltage greater than 3.59 V in the diesel oxidation catalyst inlet temperature sensor B-9127 signal circuit, this fault will occur.
  • Page 938 Electrical systems - FAULT CODES 4. Check the DOC inlet temperature sensor B-9127 vehicle harness (VE) wiring for an open circuit condition. 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 perform the following continuity check on the vehicle harness (VE) side : From Value...
  • Page 939 Electrical systems - FAULT CODES DTC 3F6-04-DOC inlet temperature sensor voltage is lower than expected Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the Diesel Oxidation Catalyst (DOC) inlet temperature sensor B-9127. If the ECU A-9000 detects a voltage less than 459.40 mV in the DOC inlet temperature sensor B-9127 signal circuit, this fault will occur.
  • Page 940 Electrical systems - FAULT CODES 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 perform the following continuity check on the vehicle harness (VE) side : From Value X-9102 pin K84...
  • Page 941 Electrical systems - FAULT CODES DTC 426-03-Level 2 Monitoring : Reported Overvoltage of Supply Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the ECU A-9000 internal 5 V supply. If the 5 V supply exceeds the maximal limit, this fault will occur.
  • Page 942 Electrical systems - FAULT CODES DTC 426-04-Level 2 Monitoring : Reported Under Voltage of Supply Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the ECU A-9000 internal 5 V supply. If the 5 V supply is below the minimal limit, this fault will occur.
  • Page 943 Electrical systems - FAULT CODES DTC 435-12-Rail pressure sensor value is intermittent Control Module : ECU NOTE: If the rail pressure 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.
  • Page 944 Electrical systems - FAULT CODES 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.
  • Page 945 Electrical systems - FAULT CODES DTC 455-03-High pressure pump fuel delivery quantity at low idle is too high Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors fuel rail pressure. If the ECU A-9000 determines that the requested fuel pressure is greater than the actual fuel pressure at idle, leakage is assumed and this fault will occur.
  • Page 946 Electrical systems - FAULT CODES DTC 459-03-Fuel metering unit intermittent electrical connection failure Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the fuel metering unit Y-9000 signal circuit. If the ECU A-9000 detects an intermittent connection in the fuel metering unit Y-9000 signal circuit, this fault will occur. Cause: The ECU A-9000 has detected a intermittent connection in the fuel metering unit Y-9000 signal circuit.
  • Page 947 Electrical systems - FAULT CODES 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.
  • Page 948 Electrical systems - FAULT CODES DTC 45A-03-Error in comparing energizing time to maximum value for injector in cylinder 3 Control Module : ECU Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection.
  • Page 949 Electrical systems - FAULT CODES DTC 45A-04-Error in comparing energizing time to minimum value for injector in cylinder 3 Control Module : ECU Context: The Zero Fuel Calibration (ZFL) evaluates energizing time for injectors at low idle. The ZFL uses learned calibration values to change the energizing time of the pilot fuel injection.
  • Page 950 Electrical systems - FAULT CODES DTC 48D-02-Throttle valve actuator control circuit open Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects a an open circuit in the throttle valve actuator Z-9001 output h-bridge circuits, this fault will occur.
  • Page 951 Electrical systems - FAULT CODES 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.
  • Page 952 Electrical systems - FAULT CODES DTC 48D-03-Throttle valve actuator control circuit over current Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects an over temperature/current condition in the throttle valve actuator Z-9001 h-bridge circuit, this fault will occur.
  • Page 953 Electrical systems - FAULT CODES B. If there is no continuity, leave connectors X-9011 and X-9001 disconnected and continue to Step 4. 4. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on the engine harness (EN) side : From Value...
  • Page 954 Electrical systems - FAULT CODES DTC 48D-12-Throttle valve actuator control circuit over temperature Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects an over temperature/current condition in the throttle valve actuator Z-9001 h-bridge circuit, this fault will occur.
  • Page 955 Electrical systems - FAULT CODES B. If there is no continuity, leave connectors X-9011 and X-9001 disconnected and continue to Step 4. 4. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short circuit condition. With the key in the OFF position, use a multimeter to perform the following continuity check for a short circuit on the engine harness (EN) side : From Value...
  • Page 956 Electrical systems - FAULT CODES DTC 4D4-03-ECU internal failure - Overvoltage monitoring error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power 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.
  • Page 957 Electrical systems - FAULT CODES DTC 4D4-04-ECU internal failure - Undervoltage monitoring error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power 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.
  • Page 958 Electrical systems - FAULT CODES DTC 4E3-03-ECU internal failure - Post injection quantity Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs a diagnostic fault check for post injection 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.
  • Page 959 Electrical systems - FAULT CODES DTC 4E3-04-Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI2 shut-off Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 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.
  • Page 960 Electrical systems - FAULT CODES DTC 4E3-12-Level 2 Monitoring : Diagnosis fault check to report the error to demand for an ICO due to an error in the PoI3 efficiency factor Control Module : ECU Context: The Engine Control Unit (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.
  • Page 961 Electrical systems - FAULT CODES DTC 52C-01-Glow Control Unit (GCU) data error Control Module : ECU Context: For information regarding the functional operation of the glow plug control module Z-9101 see Glow plug system Glow plug control module - Overview – Glow plug control module (55.202). For more information regarding glow plugs, see Glow plug system - Overview (55.202).
  • Page 962 Electrical systems - FAULT CODES 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. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires.
  • Page 963 Electrical systems - FAULT CODES DTC 532-03-Engine coolant temperature has exceeded the warning threshold Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the engine coolant temperature. Two engine temperature thresholds are monitored by the ECU A-9000, a pre-warning, and a warning. If the ECU A-9000 monitors a temperature greater than 111.96 °C (233.53 °F), a warning is set and this fault will occur.
  • Page 964 Electrical systems - FAULT CODES DTC 535-03-Maximum rail pressure exceeded Control Module : ECU NOTE: If the rail pressure 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.
  • Page 965 Electrical systems - FAULT CODES DTC 54C-03-Engine over speed condition detected Control Module : ECU Context: This fault is intended for information purposes only and does not require 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.
  • Page 966 Electrical systems - FAULT CODES DTC 559-12-Fuel metering unit has an over-temperature error Control Module : ECU Context: The Engine Control Unit (ECU) monitors the fuel metering unit Y-9000 signal circuit for an over temperature/current condition. If the ECU A-9000 detects an over temperature/current condition in the fuel metering unit Y-9000 signal circuit, this fault will occur.
  • Page 967 Electrical systems - FAULT CODES B. If there is no voltage, leave connector X-9007 disconnected and continue to Step 4. 4. Check the fuel metering unit Y-9000 low side driver engine harness (EN) wiring for a short circuit condition. 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 from the engine har- ness (EN) side : From...
  • Page 968 Electrical systems - FAULT CODES DTC 58C-03-Throttle valve actuator will not open to commanded position Control Module : ECU NOTE: Once repaired, this fault may take up to up to 10 min of operation to reset. Context: The Engine Control Unit (ECU) A-9000 monitors the Throttle Valve Actuator (TVA) Z-9001. The TVA Z-9001 provides the ECU A-9000 with a feedback using a position sensor.
  • Page 969 Electrical systems - FAULT CODES DTC 58C-04-Throttle valve actuator will not close to commanded position Control Module : ECU NOTE: Once repaired, this fault may take up to up to 10 min of operation to reset. Context: The Engine Control Unit (ECU) A-9000 monitors the Throttle Valve Actuator (TVA) Z-9001. The TVA Z-9001 provides the ECU A-9000 with a feedback using a position sensor.
  • Page 970 Electrical systems - FAULT CODES DTC 58D-03-Throttle valve actuator control circuit high side shorted to battery Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects a short to high source condition in the throttle valve actuator Z-9001 output 1 h-bridge circuit, this fault will occur.
  • Page 971 Electrical systems - FAULT CODES B. If there is no continuity, leave connectors X-9011 and X-9001 disconnected and continue to Step 4. 4. Check the throttle valve actuator Z-9001 engine harness (EN) wiring for a short to high source condition. With the key in the OFF position, use a multimeter to perform the following continuity check on the engine harness (EN) side : From...
  • Page 972 Electrical systems - FAULT CODES DTC 58D-04-Throttle valve actuator control circuit high side shorted to ground Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors the throttle valve actuator Z-9001 output 1 and output 2 h-bridge circuits. If the ECU A-9000 detects a short to ground condition in the throttle valve actuator Z-9001 output 1 h-bridge circuit, this fault will occur.
  • Page 973 Electrical systems - FAULT CODES A. If there is continuity, there is a short circuit in the throttle valve actuator Z-9001 output 1 h-bridge circuit. Locate and repair the shorted conductor. B. If there is no continuity, leave the connector X-9011 disconnected and continue to Step 4. 4.
  • Page 974 Electrical systems - FAULT CODES DTC 5D2-03-ECU internal failure - EEPROM memory failure Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 calculates the correction values from the EEPROM. If the ECU A-9000 detects an error n the EEPROM block, this fault will occur. Solution: 1.
  • Page 975 Electrical systems - FAULT CODES DTC 5D4-02-ECU internal failure - WDA is not working correctly Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant 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.
  • Page 976 Electrical systems - FAULT CODES DTC 5D4-03-ECU internal failure - Alarm task period error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel 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.
  • Page 977 Electrical systems - FAULT CODES DTC 5D4-04-ECU internal failure - Positive test failed Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages 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.
  • Page 978 Electrical systems - FAULT CODES DTC 5D4-12-ECU internal failure - Timeout in the shut off path test error Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 performs “shut-off paths” which deactivate all power stages relevant to fuel injection if certain ECU A-9000 errors are detected.
  • Page 979 Electrical systems - FAULT CODES DTC 5E3-03-ECU internal failure - Torque request due to fuel pressure exceeds maximum torque limit Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors “lead torque”, which is the input torque request that is calculated for determining fuel pressure.
  • Page 980 Electrical systems - FAULT CODES DTC 5E3-04-ECU internal failure - Torque request due to air control exceeds maximum torque limit Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 monitors “lead torque”, which is the input torque request that is calculated for determining fuel pressure.
  • Page 981 Electrical systems - FAULT CODES DTC 5E3-12-ECU internal failure - Torque request exceeds maximum torque limit Control Module : ECU Context: The Engine Control Unit (ECU) A-9000 calculates and monitors “inner torque”, torque produced by the 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.
  • Page 982 Electrical systems - FAULT CODES DTC 601-02-Lambda sensor nernst cell open circuit Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 983 Electrical systems - FAULT CODES 4. 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.
  • Page 984 Electrical systems - FAULT CODES DTC 602-02-Lambda sensor pump current open circuit Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 985 Electrical systems - FAULT CODES 4. 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.
  • Page 986 Electrical systems - FAULT CODES DTC 605-03-Lambda sensor O2 value above maximum threshold Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 987 Electrical systems - FAULT CODES 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 condition and verify that the error has been resolved.
  • Page 988 Electrical systems - FAULT CODES DTC 606-02-Lambda sensor virtual ground open circuit Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 989 Electrical systems - FAULT CODES 4. 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.
  • Page 990 Electrical systems - FAULT CODES DTC 607-03-Lambda sensor O2 calibrator too high error Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 991 Electrical systems - FAULT CODES DTC 607-04-Lambda sensor O2 calibrator too low error Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 992 Electrical systems - FAULT CODES DTC 609-02-ECU internal failure - SPI chip error configuration Control Module : ECU Context: The SPI chip, which is internal to the ECU A-9000, controls the Lambda sensor B-9123 device for the measuring or the calibrating of the inner resistance for temperature evaluation, switches on and off the pump current to measure O2 content and monitors the hardware related to the open load and short circuit monitoring devices.
  • Page 993 Electrical systems - FAULT CODES DTC 60A-04-Lambda sensor heater battery voltage too low Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 994 Electrical systems - FAULT CODES 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.
  • Page 995 Electrical systems - FAULT CODES DTC 60B-03-Lambda sensor cell circuits short circuit to battery Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 996 Electrical systems - FAULT CODES A. If there is no continuity or voltage, leave connector X-9123 and connector X-9102 disconnected and continue to Step 3. B. If there is continuity or voltage, there is a short circuit condition is in the lambda sensor B-9123 wiring in the vehicle harness (VE).
  • Page 997 Electrical systems - FAULT CODES DTC 60B-04-Lambda sensor cell circuits short circuit to ground Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 998 Electrical systems - FAULT CODES 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. 4. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires.
  • Page 999 Electrical systems - FAULT CODES DTC 60C-03-Lambda sensor estimated temperature higher than threshold Control Module : ECU NOTE: If the Lambda sensor B-9123 is replaced, it is necessary to perform the Replacement of the Lambda Sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Lambda sensor - Configure - Reset ECU data (Lambda sensor) (55.989), if necessary.
  • Page 1000 Electrical systems - FAULT CODES 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 harnesses and connectors for damage, bent or dislocated pins, corroded terminals, or broken wires.

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