New Holland Tractor TM120, TM130, TM140, TM155, TM175, TM190 Repair Manual 6045511102 – PDF DOWNLOAD

Description

New Holland Tractor TM120, TM130, TM140, TM155, TM175, TM190 Repair Manual

FILE DETAILS:

New Holland Tractor TM120, TM130, TM140, TM155, TM175, TM190 Repair Manual

Size: 137 MB
Format: PDF
Language: English
Number of Pages : 7682 pages
Brand: New Holland
Type of document: Repair Manual
Model: TM120, TM130, TM140, TM155, TM175, TM190
Part No: 6045511102

NEW HOLLAND TRACTOR TM120, TM130, TM140, TM155, TM175, TM190 REPAIR MANUAL 6045511102 – PDF DOWNLOAD:

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DESCRIPTION:

New Holland Tractor TM120, TM130, TM140, TM155, TM175, TM190 Repair Manual 

Generalities:

• Carefully follow specified repair and maintenance procedures.
• Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught on moving parts. Use approved safety clothing such as anti–slipping footwear, gloves, safety goggles, helmets, etc.
• Wear safety glasses with side guards when cleaning parts using compressed air. • Damaged or frayed wires and chains are unreliable. Do not use them for lifting or towing.
• Wear suitable protection such as approved eye protection, helmets, special clothing, gloves and footwear whenever welding. All persons standing in the vicinity of the welding process should wear approved eye protection. NEVER LOOK AT THE WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED.
• Never carry out any repair on the machine if someone is sitting on the operator’s seat, except if they are qualified operators assisting in the operation to be carried out.
• Never operate the machine or use attachments from a place other than sitting at the operator’s seat or at the side of the machine when operating the fender switches.
• Never carry out any operation on the machine when the engine is running, except when specifically indicated. Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc.
• All repair and maintenance operations should be carried out with the greatest care and attention.
• Disconnect the batteries and label all controls to warn that the tractor is being serviced. Block the machine and all equipment which should be raised.
• Never check or fill fuel tanks or batteries, nor use starting liquid if you are smoking or near open flames as such fluids are flammable.
• The fuel filling gun should always remain in contact with the filler neck. Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity build–up.
• To transfer a failed tractor, use a trailer or a low loading platform trolley if available.
• To load and unload the machine from the transportation means, select a flat area providing a firm support to the trailer or truck wheels. Firmly tie the machine to the truck or trailer platform and block wheels as required by the transporter.
• Always use lifting equipment of appropriate capacity to lift or move heavy components.
• Chains should always be safely fastened. Ensure that fastening device is strong enough to hold the load foreseen. No persons should stand near the fastening point.
• The working area should be always kept CLEAN and DRY. Immediately clean any spillage of water or oil.
• Never use gasoline, diesel oil or other flammable liquids as cleaning agents. Use non–flammable non–toxic proprietary solvents.
• Do not pile up grease or oil soaked rags, as they constitute a great fire hazard. Always place them into a metal container.

TABLE OF CONTENTS:

New Holland Tractor TM120, TM130, TM140, TM155, TM175, TM190 Repair Manual 

GENERAL SECTION 00
General Instructions and Health and Safety Chapter 1
ENGINE SECTION 10
Separating and Removing The Engine Chapter 1
Section Description Page
Torques 2
Special Tools3
10 100 Separating Front Axle and Front Support from Engine 4
Separating Engine and Front Support from Transmission 14
10 100 Engine Removal 21
75L CNH Engine Chapter 2
Section Description Page
10 000 Specifications 2
Greases and Sealants 8
Tightening Torques10
Special Tools 12
Fault Finding 13
Description and Operation17
10 001 Engine Overhaul–Introduction 24
Injection Pump Timing Check 25
10 100 Engine Disassembly and Overhaul:–
10 101 Cylinder Head, Valves and Related Parts 28
10 101 Hydraulic Tappets–Adjustment 38
10 106 Front Cover and Timing Gears 40
10 102 Oil Pan 44
10 103 Flywheel 45
10 102 Rear Cover Plate 46
10 102 Oil Pump 47
Contents Continued:
6045511102 –02–2006 ii
Section Description Page
10 102 Oil Pressure Relief Valve 49
10 106 Camshaft, Tappets and Camshaft Bearings 50
10 105 Pistons and Cylinder Block 53
10 103 Crankshaft 62
10 003 Crankshaft Front Seal Installation 66
10 001 Engine compression test 67
10200 Cooling System
Description of Operation 68
Troubleshooting 70
Specifications 71
Overhaul 72
Fuel System Chapter 3
Section Description Page
10 200 Specifications 2
Torques 2
Special Tools3
Description and Operation 4
Bosch VE Type Mechanically Controlled Fuel Injection System — Removal 8
Bosch VE Type Pump Timing and Installation 9
Bosch VP Electronically Controlled Fuel Injection System — Removal 13
Bosch VP Electronically Controlled Fuel Injection System — Timing Check14
Injection System Bleeding17
Injection System Testing and Overhaul 18
10 210 Electric Lift Pump — Removal 23
Electric Lift Pump — Testing 23
10 250 Turbocharger — Removal 24
Turbocharger — Dissassembly 25
Turbocharger — Inspection — Reassembly– Installation 25
10 202 Air Cleaner — Removal — Overhaul 28
10 216 Main Fuel Tank — Removal and Installation 31
Auxiliary Fuel Tank — Removal and Installation32
Crankcase Ventilation 32
10 220 Foot Throttle Cable — Replacement and Adjustment 33
Hand Throttle Cable — Replacement and Adjustment 33
Contents Continued:
iii 6045511102 –02–2006
CLUTCHES SECTION 18
Clutches Chapter 1
Section Description Page
18 000 Specifications 1
Tightening Torques 2
Sectional Views 3
Special Tools4
Description and Operation 4
Troubleshooting 4
18 110 Clutch Removal–Installation 6
18 104 Hydraulic Control Assembly Removal–Installation 8
Hydraulic Control Assembly Disassembly–Reassembly 10
TRANSMISSION SYSTEM SECTION 21
Semi–Powershift Transmission (Range Command) Chapter 1
Section Description Page
21 000 Specifications 1
Tightening Torques 3
Special Tools5
Sectional Views 9
Description and Operation12
Pressure Testing 20
Calibration 24
Fault Findingsee Section 55
21 111 Removal — Installation — Overhaul 27
Power Command 30 and 40 kph Transmission, 120 — 155 Models
(Full Powershift) Chapter 2
Section Description Page
21 000 Specifications 2
Tightening Torques 5
Special Tools 10
Transmission Cross Section 13
Description and Operation and Power Flows 16
Clutch Calibrations34
Pressure Testing 39
Error Codes and Fault Finding 42
Limp Home Tool 46
21 113 Transmission Removal and Installation 47
21 155 Transmission Overhaul — Disassembly 53
21 155 Transmission Overhaul — Reassembly 78
Contents Continued:
6045511102 –02–2006 iv
Power Command Transmission, 175 — 190 Models
(Full Powershift) Chapter 3
Section Description Page
21 000 Specifications 2
Tightening Torques 5
Special Tools7
Description and Operation10
Power Flows 18
Input Sensors and Output Devices 24
Controls 27
Clutch Calibration 40
Pressure Testing 44
Error Codes and Fault Finding 47
Limp Home 51
21 113 Transmission Housing — Removal and Installation 52
21 155 Transmission Disassembly 59
21 155 Oil Manifold Bushes, Removal and Installation72
21 155 Transmission Upper Speed Shaft End Float Adjustment 73
21 155 Clutch Overhaul 74
21 155 Transmission Rear Housing — Disassembly 86
21 155 Transmission Reassembly88
21 155 Output Shaft End Flow Adjustment 96
21 155 Medium Shaft End Float Adjustment 97
Dual Command Transmission (HI–LO) Chapter 4
Section Description Page
21 000 Specifications 1
Tightening Torques 4
Special Tools6
Sectional Views 10
Description and Operation12
Clutch and Synchroniser Calibration 16
Pressure Testing 19
Error Codes and fault Finding 22
Limp Home 28
21 112 Transmission Removal and Installation29
Transmission Overhaul 32
Shuttle Gear Bearing Adjustment46
Range Input and Output Shaft Bearing Adjustment 48
21 134 HI LO Transmission Valve — Overhaul 51
21 134 HI LO Transmission Control Assembly 54
Contents Continued:
v 6045511102 –02–2006
Shuttle Command (Mechanical Transmission) Chapter 5
Section Description Page
21 000 Specifications 2
Tightening Torques 4
Special Tools6
Sectional Views 10
Description and Operation14
Troubleshooting 14
21 114 Mechanical Transmission Housing Removal — Installation 15
21 114 Mechanical Transmission Housing Removal — Overhaul 18
21 114 Mechanical Transmission Housing Adjustments 31
21 140 Mechanical Transmission Housing Removal — Installation 5th Speed Gear 35
21 130 Speed and Range Control Rail Assembly Removal — Installation 40
21 160 Creeper Gears Removal — Installation 42
21 160 Creeper Gears External Control Lever adjustment 43
DRIVE LINES (FWD ELECTRO–HYDRAULIC CLUTCH) SECTION 23
Drive Lines–Tractors with Dual Command and Shuttle Command
Transmissions Chapter 1
Section Description Page
23 000 Specifications 1
Tightening Torques 2
Special Tools2
Sectional Views 4
Description and Operation 5
Troubleshooting 5
Hydraulic Flow Diagrams 6
23 101 Removal–Installation–Overhaul 8
Drive Lines–Tractors with Range Command and
Power Command ( Full Powershift) Transmissions Chapter 2
Section Description Page
23 000 Specifications 2
Tightening Torques 2
Special Tools2
Sectional Views 3
Troubleshooting 4
Description and Operation 5
Hydraulic Flow Diagrams 6
23 101 Drive shaft Removal–Installation 8
23 202 Electro Hydraulic Clutch Removal–Installation–Overhaul 9
Contents Continued:
6045511102 –02–2006 vi
MECHANICAL FRONT AXLE SECTION 25
Mechanical Front Axle Chapter 1
Section Description Page
25 000 Specifications 1
Tightening Torques 2
Special Tools 4
Sectional Views 7
Description and Operation 8
Troubleshooting 11
25 100 Standard Axle — Removal/Installation 12
Suspended Axle — Removal/Installation 15
Super steer Axle — Removal/Installation 20
Hub Cassette Seal Replacement 24
Front Axle Overhaul — All Options 28
Dog Clutch Differential Lock — Disassembly/Reassembly 34
Multi Wet Plate Differential Lock — Disassembly/Reassembly 36
25 102 Crown Wheel/Differential — Disassembly/Reassembly — All Options 38
Pinion Shaft Removal — All Options 39
Pinion Shaft Adjustment/Installation — All Options 42
Crown Wheel Adjustments — All Options 50
Swivel Pin & Potentiometer — Disassembly/Reassembly 53
Axle Reassembly — All Options 57
Checking the Alignment of Steering and Drive Wheels 58
Refer to Brake Section Of Repair Manual For Overhaul Of Front Axle Brakes Where
Fitted
Terraglide (Front Axle Suspension) Chapter 2
Section Description Page
25 000 Specifications 2
Tightening Torques 2
Description and Operation 3
System Schematics6
Suspended Front Axle Calibration Procedure 18
Error Code Listing 20
25 100 Suspended Front Axle Assembly–Removal and Installation 22
25 100 Suspension Cylinder Removal and Overhaul 30
Suspension Control Valve Assembly–Removal 34
Suspension Control Valve Assembly–Overhaul 35
Contents Continued:
vii 6045511102 –02–2006
MECHANICAL REAR WHEEL DRIVE (Rear Axle) SECTION 27
Mechanical Rear Wheel Drive (Models 120 — 155) Chapter 1
Section Description Page
27 000 Specifications 2
Tightening Torques 4
Special Tools6
Sectional Views 9
Description and Operation 11
Fault Finding 14
27 100 Rear Axle Housing — Removal and Installation16
27 100 Rear Axle Housing — Overhaul 21
Rear Axle Adjustments 30
Pinion and Crown Wheel Adjustments 31
Hydraulic Pump Idler Gear Bearing Adjustment 37
27 106 Hydraulic Differential Lock — Removal and Installation40
27 110 Hydraulic Differential Lock Control Unit — Dog Type Clutch 44
27 110 Hydraulic Differential Lock Control Unit — Multi Plate Clutch46
27 120 Final Drive Case — Removal and Installation 47
27 120 Drive Wheel Shaft — Removal and Installation 51
Mechanical Rear Wheel Drive (175–190 Models) Chapter 2
Section Description Page
27 000 Specifications 1
Tightening Torques 3
Special Tools5
Sectional Views 7
Description and Operation 9
Troubleshooting 11
27 100 Removal — Installation — Overhaul 13
Rear Axle Adjustments 28
27110 Hydraulic Differential Lock Control 36
50KPH Clutch 40
27120 Drive Wheel Shaft — Removal– Installation 49
POWER TAKE–OFF SECTION 31
Rear Power Take–Off, 120–155 Models Chapter 1
Section Description Page
31 000 Specifications 1
Tightening Torques 3
Special Tools3
Sectional Views 4
Contents Continued:
6045511102 –02–2006 viii
Description and Operation 6
Hydraulic Flow Diagrams 11
Fault Finding 14
31 100 Removal–Installation–Overhaul 16
Ground Speed Interlock Switch Adjustment 27
Section Description Page
Rear Power Take–Off, 175–190 Models Chapter 2
Section Description Page
31 000 Specifications 2
Tightening Torques 4
Special Tools5
Sectional Views 6
Description and Operation 8
Hydraulic Operation of Power Take Off (PTO) 12
Fault Finding 18
31 100 Removal–Installation–Overhaul 20
Calibration 29
Hydraulic Front Lift and Power Take Off Chapter 3
Section Description Page
31 000 Specifications 2
Torques 2
Description and Operation
35 162 Front Hydraulic Lift 3
31 146 Front PTO 5
Fault Finding 10
Overhaul
35 162 Front Hydraulic Lift 11
31 142 Front PTO16
Hydraulic and Electrical Connections 24
BRAKING SYSTEM SECTION 33
Tractor Brakes Chapter 1
Section Description Page
33 000 Specifications 2
Special Tools3
Tightening Torques 5
Sectional Views 5
Description and Operation 8
Operation, Power Brake Coloured Diagrams 11
Fault Finding 15
Tasks Before Carrying Out Brake Overhaul 17
Contents Continued:
ix 6045511102 –02–2006
33 202 Removal–Installation–Overhaul, Service Brakes Models 120–155 17
33 202 Removal–Installation–Overhaul, Service Brakes Models 175–190 21
33 202 Removal–Installation–Overhaul, Front Brakes All Models 26
33 202 Removal–Installation, Service Brake Master Cylinder32
33 202 Pedal Adjustments, Service Brakes 33
33 202 Removal–Installation, Front Brake Booster 35
33 202 Overhaul, Front Brake Booster 37
33 202 Hydraulic Brake System, Air Bleeding 38
33 110 Removal–Installation–Overhaul, Parking Brake Assembly 42
33 110 Handbrake Control–Travel Adjustment 46
Pneumatic Trailer Brakes Chapter 2
Section Description Page
33 000 Specifications 1
Tightening Torques 2
Description and Operation 3
Fault Finding 13
33 000 Removal and Installation 15
33 000 Overhaul 20
Pressure Testing 30
Contents Continued:
6045511102 –02–2006 x
CONTENTS — VOLUME 2
HYDRAULIC SYSTEMS SECTION 35
Introduction Chapter 1
Section Description Page
35 000 Introduction and Circuit Identification 2
Closed Centre Load Sensing High Pressure Hydraulic Circuits 8
Open Centre High Pressure Hydraulic Circuit 22
Low Pressure Hydraulic Circuits
Tractors with Power Command Transmission — 175 and 190 Models 27
Tractors with Power Command Transmission — 120 to 155 Models 35
Tractors with Range Command Transmission 41
Tractors with Dual Command Transmission 45
Tractors with Shuttle Command Transmission 50
General Hydraulic Fault Finding 54
Initial Fault Finding Check54
Transmission Low Pressure Warning Light ‘ON’55
Charge Pressure Light 56
Intake Filter Restriction Warning Light 56
Power Steering 57
Trailer Brakes 57
Hydraulic Lift58
Remote Control Valves 59
Variable Flow Hydraulic Pump Assembly
120 to 155 Models Chapter 2
Section Description Page
35 000 Special Tools1
Specifications 2
Tightening Torques 3
Description and Operation 4
Hydraulic Circuit Operation 12
Low Pressure Standby 14
High Pressure Circuit High Demand 16
High Pressure Circuit Low Demand 17
Controlling Maximum System Pressure 18
Fault Finding 19
Initial Fault Finding Check19
Transmission Low Pressure Warning Light ‘ON’21
Charge Pressure Light 23
Intake Filter Restriction Warning Light 23
Power Steering 24
Trailer Brakes 24
Contents Continued:
xi 6045511102 –02–2006
Hydraulic Lift25
Remote Control Valves 26
Pump Pressure and Flow Testing27
Low Pressure Standby 27
High Pressure Standby 28
Load Sensing Circuit Test 29
Charge Pressure Test 29
Variable Flow Piston Pump Flow Test 30
Steering Pump/Low Pressure Pump Test 31
Hydraulic Pump Leak Test32
35 106 Overhaul 33
Charge Pressure Valve 34
Charge Pressure Filter Dump Valve 34
Steering Flow Control Valve 35
Pressure and Flow Compensating Valve 36
Pump Removal and Installation 38
Steering Pump Overhaul 41
Charge Pump Overhaul 43
Variable Flow Piston Pump Overhaul 45
Pump Drive Gear and Bearing Overhaul 48
Contents Continued:
6045511102 –02–2006 xii
Variable Flow Hydraulic Pump Assembly
175 to 190 Models Chapter 3
Section Description Page
35 000 Special Tools2
Specifications 3
Tightening Torques 4
Description and Operation 6
Hydraulic Circuit Operation 14
Generating Low Pressure Standby 16
Regulating Low Pressure Standby 18
High Pressure Circuit High Demand 20
High Pressure Circuit Low Demand 22
Limiting Maximum System Pressure 24
Low Pressure Regulating valve operation 26
Fault Finding 29
Initial Fault Finding Check29
Transmission Low Pressure Warning Light ‘ON’30
Charge Pressure Light 31
Intake Filter Restriction Warning Light 31
Power Steering 32
Trailer Brakes 32
Hydraulic Lift33
Remote Control Valves 34
Pump Pressure and Flow Testing36
Low Pressure Standby 36
High Pressure Standby 37
Load Sensing Circuit Test 38
Charge Pressure Test 38
Variable Flow Piston Pump Flow Test 39
Steering Pump/Low Pressure Pump Test 40
Hydraulic Pump Leak Test41
35 106 Overhaul 42
Steering Pump Overhaul 43
Steering Flow Control Valve 45
Pressure and Flow Compensating Valve 46
Pump Removal and Installation 48
Charge Pump Overhaul 52
Variable Flow Piston Pump Overhaul 54
Contents Continued:
xiii 6045511102 –02–2006
Hydraulic Lift Assembly with Electronic Draft Control Chapter 4
Section Description Page
35 000 Specifications 2
Special Tools2
Tightening Torques 3
Description and Operation 4
Principal of Draft Control4
Components 7
Operation of Draft Control 13
Hydraulic Operation of Lift Control Valve 16
Trouble Shooting and Calibration24
Overhaul
35 138 Electronic Draft Control Valve — Removal and Installation33
35 138 Disassembly 35
35 130 Load Sensing Pin Replacement 40
35 134 Hydraulic Lift Cover — Removal and Installation (120 to 155 Models Only) 41
35 134 Disassembly 44
Mechanical Rear Hydraulic Lift Chapter 5
Section Description Page
35 000 Specifications 1
Tightening Torques 3
Special Tools5
Sectional Views 6
Description and Operation 9
Troubleshooting 13
35 114 Removal — Installation — Overhaul 15
Section Description Page
Closed Centre Remote Control Valves Chapter 6
Section Description Page
35 000 Special Tools2
Specifications 2
Tightening Torques 2
Fault Finding and Pressure Testing Mechanical Remote Valves 3
Fault Finding and Pressure Testing Electro–Hydraulic Remote Valves 4
Electro–Hydraulic Remote Valve Fault Code list6
Description and Operation — Mechanical Remote Valves 7
Oil Flow In Neutral12
Oil Flow in Raising (Cylinder Extend) 14
Oil Flow in Lowering (Cylinder Retract) 16
Oil Flow in Float 18
Contents Continued:
6045511102 –02–2006 xiv
Section Description Page
Operation of Detent Pressure Regulating Valve 20
Operation of Two or More Control Valves Simultaneously 23
Description and Operation — Electro–Hydraulic Remote Valves 25
Re–Calibrating Remote Valve Levers 34
Oil Flow In Neutral40
Oil Flow in Raising (Cylinder Extend) 42
Oil Flow in Lowering (Cylinder Retract) 44
Oil Flow in Float 46
Operation of Two or More Control Valves Simultaneously 49
35 204 Overhaul — Mechanical Remote Valves51
Individual Valve Section Removal 51
Complete Valve Stack Removal 53
Remote Valve Disassembly 55
Overhaul — Electro–Hydraulic Remote Valves 61
Electro–Hydraulic Remote Valves Number Programming 62
Electro–Hydraulic Remote Valves Removal and Installation 64
Electro–Hydraulic Remote Valve Disassembly68
Open Centre Remote Control Valves Chapter 7
Section Description Page
35 000 Specifications –Tightening Torques 1
Special Tools2
Sectional Views 3
Description and Operation 6
35 204 Removal — Installation — Overhaul11
External Lift Rams Chapter 8
Section Description Page
120 TO 155 MODELS
35 000 Specifications 2
Sectional Views 2
Description and Operation 3
35 116 Removal — Installation — Overhaul3
Disassembly — Reassembly 3
175 AND 190 MODELS
35 000 Specifications 4
Sectional Views 4
Description and Operation 5
35 116 Removal — Installation — Overhaul5
Disassembly — Reassembly 6
Contents Continued:
xv 6045511102 –02–2006
Hydraulic Pressure Testing Chapter 9
Section Description Page
35 000 Introduction 3
Special Tools4
Specifications 5
Variable Displacement Hydraulic Pump Installation 6
Open Centre Hydraulic Pump Installation8
Fault Finding8
Transmission Low Pressure Warning Light On 9
Charge Pressure Light Flashing 11
Intake Filter Restriction Light On 11
Power Steering Not Working Correctly 12
Trailer Brakes Not Working Correctly 13
Hydraulic Lift Not Working Correctly 14
Remote Control Valves Not Working 16
Pump Pressure and Flow Testing18
Low Pressure Standby 18
High Pressure Standby 19
Lift Ram Pressure Test 20
Load Sensing Circuit Test21
Charge Pressure Test 22
Variable Flow Piston Pump Flow Test 23
Hydraulic Pump Leak Test 24
Steering Pump/Low Pressure Pump Test 25
Steering Test 25
Steering Circuit Pressure Test 25
Steering Relief Valve Pressure Test 26
Low Pressure Test26
Open Centre Lift Pressure Regulating Valve 29
Power Command Transmission Clutch Pressure Test30
Range Command Transmission Clutch Pressure Test34
Dual Command Transmission Clutch Pressure Test 37
Trailer Brake Testing and Troubleshooting 40
Trailer Brake Valve Electro–Hydraulic Operation Diagram (Italy Only) 40
Trailer Brake Disengagement Pressure Test (Italy Only) 41
Trailer Brake System Pressure Test 42
Trailer Brake System Leak Test 42
Trailer Brake Engagement Test (Italy Only) 43
Trailer Brake Circuit Safety Switch Test43
Contents Continued:
6045511102 –02–2006 xvi
Section Description Page
Cooler By–pass Valve — Lubrication Pressure 44
PTO Clutch lubrication (175 and 190 Models) 44
Brake Booster Valve Pressure Test 44
Power Brake Supply and Accumulator Test (175 and 190 Models) 45
Fixed Displacement Gear Pumps Chapter 10
Section Description Page
35 000 Specifications 1
Tightening Torques 3
Special Tools4
Sectional Views — Description and Operation 5
Troubleshooting see Chapter 5
35 104 Removal — Installation — Overhaul6
Trailer Brake Auxiliary Valves Chapter 11
Section Description Page
35 000 Specifications 2
Torques 2
Special Tools2
Description and Operation 3
33 220 Italian Trailer Brakes 10
Pressure Testing 17
Hydraulically Adjustable Right Hand Lift
and Top Link Cylinders Chapter 12
Section Description Page
35 000 Specifications 1
Sectional Views 2
Tightening Torques 3
Description and Operation 4
Removal — Installation — Overhaul5
Mid Mount Remote Valves Chapter 13
Section Description Page
Specifications 2
Torque Values 3
Description and Operation 4
Mid Mount Valve Hydraulic Circuit 120 — 155 Models 9
Mid Mount Valve Hydraulic Circuit 175 — 190 Models 11
Mid Mount Valve Removal 15
Mid Mount Valve Disassembly 15
Mid Mount Valve Overhaul 17
Contents Continued:
xvii 6045511102 –02–2006
Mid Mount Valve Installation 20
Third Mid Mount Valve — Description and Operation 21
Removal 23
Disassembly 23
Re–assembly 24
STEERING SYSTEMS SECTION 41
Hydrostatic Steering Systems Chapter 1
Section Description Page
41 000 Specifications 2
Tightening Torques 3
Special Tools3
Description and Operation 4
Fault Finding11
System Testing 12
41 204 Steering Motor — Removal and Installation 14
Steering Motor Overhaul 16
Steering Column — Removal and installation 24
41 216 Two Wheel Drive Steering Cylinder — Removal and Installation 26
Two Wheel Drive Steering Cylinder — Overhaul27
Four Wheel Drive Steering Cylinder — Removal and Installation 28
Four Wheel Drive Steering Cylinder — Overhaul 29
FRONT AXLE SECTION 44
Front Axle and Wheels Chapter 1
Section Description Page
44 000 Specifications 1
Tightening Torques 3
Special Tools5
Description and Operation 5
Troubleshooting 5
Sectional Views 6
44 101 Removal — Installation — Overhaul9
44 511 Front Wheel Camber and Toe–in (Standard Duty Axle) 20
Front Wheel Camber and Toe–in (Heavy Duty Axle) 23
AUXILIARY UNITS SECTION 50
Contents Continued:
6045511102 –02–2006 xviii
Air Conditioning Chapter 1
Section Description Page
50 000 Specifications 2
Tightening Torques 2
Special Tools2
Safety Precautions 2
Description and Operation 4
Fault Finding and System Testing 15
Leak Testing, Charging, Discharging and System Flushing 32
Component Overhaul (excluding compressor) 37
50 200 Compressor Removal and Installation 44
50 200 Compressor Overhaul 44
ELECTRICAL SYSTEM SECTION 55
Electrical Introduction Chapter 1
Section Description Page
55 100 Electrical System and Fuses Description1
Fuses and Relays 4
Controllers 10
Diagnostic Connectors 13
System Precautions For Battery Charging and Welding 14
Temporary Wiring Repair 15
System Diagrams 17
Electronic Management Unit and Digital Instrument Cluster (175 &190 Models) 18
Central Controller (XCM) (175 & 190 Models) 20
Secondary Controller (EDC and Transmission) (175 & 190 Models) 22
Engine Control Module (175 & 190 Models) 24
Electro–Hydraulic Remote Valves (175 & 190 Models)26
Electronic Management Unit and Digital Instrument Cluster
Power Command (120 to 155 Models) 28
Secondary Controller ( Power Command EDC and Transmission)
(120 to 155 Models)30
General Control Module (GCM) (Power Command — Front Suspension)
(120 to 155 Models)32
Small Control Module (Vistronic Fan) (All 120 to 155 Models)34
Electronic Management Unit and Digital Instrument Cluster
Range Command (120 to 155 Models) 36
General Control Module (GCM) (Range Command — EDC and Front Suspension)
(120 to 155 Models)38
Transmission Control Module (TCM) (Range Command) (120 to 155 Models) 40
Electronic Management Unit and Digital Instrument Cluster
Dual Command (120 to 155 Models) 42
General Control Module (GCM) (Dual Command — Transmission and EDC)
(120 to 155 Models)44
Contents Continued:
xix 6045511102 –02–2006
Electronic Management Unit (EMU) Chapter 2
Section Description Page
55 440 Introduction 1
Worklamp Operation2
Functions controlled by the Electronic Management Unit 2
Electronic Management Unit with Terralock t 3
Touch Panels t 5
Calibrations 6
Brake Switch Adjustment 7
Removal and Installation 7
Error Codes 8
Electronic Instrument Cluster Chapter 3
Section Description Page
55 100 Introduction 2
Senders and Sensors 9
Programming Central LCD 21
Programming Performance Monitor 23
Serviceability 25
Fault Codes26
Diagnostic Memory27
Instrument Panel Byte Level Set–up 28
Software Revision Level Check 29
Analogue Electronic Instrument Cluster Chapter 4
Section Description Page
55 100 Introduction 1
Senders and Sensors 5
Serviceability11
Analogue Instrument Cluster Chapter 5
Section Description Page
55 100 Introduction 1
Senders, Sensors and Switches 4
Serviceability9
Contents Continued:
6045511102 –02–2006 xx
Starting System Chapter 6
Section Description Page
55 000 Specifications 1
Tightening Torques 1
Description and Operation 2
Fault Finding5
System Testing 6
55 201 Removal and Installation 8
Overhaul 8
Bench Tests 11
Charging System Chapter 7
Section Description Page
55 000 Specifications 1
Tightening Torques 1
Description and Operation 2
Fault Finding4
55 301 Removal, Installation and Overhaul 10
Battery Chapter 8
Section Description Page
55 000 Specifications 1
Description and Operation 1
55 300 Removal and Installation 2
Battery Maintenance and Testing 3
Battery Charging 4
Common Causes of Battery Failure 7
Wiring Diagrams Chapter 9
Description Page
Wiring Diagram Circuit Descriptions (All Models) 1
How To Use The Linear Wiring Diagrams 2
Symbols 4
Component Identification and Wiring Diagram Location Key 5
Wiring Diagrams:
Full PowerShift Transmission 175 & 190 Models 13
Full PowerShift Transmission, 120 to 155 Models 73
Semi–PowerShift Transmission, 120 to 155 Models 133
Dual Command Transmission, 120 to 140 Models 193
Shuttle Command Transmission, 120 to 140 Models 253
Wire Identification Key 313
Contents Continued:
xxi 6045511102 –02–2006
CONTENTS — VOLUME 3 & 4
Fault Codes Chapter 10
Section Description Page
55 000 Introduction 3
Special Tools4
Wiring Harness Repairs 4
Digital Multi–Meter — Basic Operation 7
Electrical Test Procedures10
Circuit Components — Basic Description13
Fault Code ’Logic’ and Display Areas 24
Displaying and Clearing Fault Codes 31
Fault Code Lists 39
Fault Code Charts 175 & 190 Models with Power Command Transmission
Power Command Transmission (’F’ codes) 87
Electronic Draft Control (No prefix) 301
Suspended Front Axle (’L’ codes) 399
Power Take Off (’P’ codes) 445
Electronic Management Unit (’P’ codes) 485
Digital Instrument Cluster (No prefix) 519
Electronic Hydraulic Remotes (’R’ & ’Flash’ codes) 551
Hand throttle and PTO Torque (’T’ codes) 683
Engine (’T’ codes)735
Fault Code Charts 120 to 155 Models with Power Command Transmission
Power Command Transmission (’F’ codes) 953
Electronic Draft Control (No prefix) 1129
Suspended Front Axle (’L’ codes) 1225
Electronic Management Unit (’P’ codes) 1269
Digital Instrument Cluster (No prefix)1349
Fault Code Charts 120 to 155 Models with Range Command Transmission
Range Command Transmission (’F’ codes) 1379
Electronic Draft Control (No prefix) 1541
Suspended Front Axle (’L’ codes) 1635
Electronic Management Unit (’P’ codes) 1679
Digital Instrument Cluster (No prefix)1759
Contents Continued:
6045511102 –02–2006 xxii
Section Description Page
Fault Code Charts 120 to 155 Models with Dual Command Transmission
Dual Command Transmission (’E’ codes) 1789
Electronic Draft Control (No prefix) 1903
Electronic Management Unit (’P’ codes) 1995
Digital Instrument Cluster (No prefix) 2075
Fault Code Charts 120 to 140 Models with Suttle Command Transmission
Electronic Management Unit (’P’ codes) 2105
CONTENTS — VOLUME 5
ELECTRICAL SYSTEM SECTION 55
Diagnostic ’H’ Routines Chapter 11
Section Description Page
55 000 Introduction 2
Power Command Transmission “H” Routine 3
Range Command Transmission “H” Routine 18
Dual Command Transmission “H” Routine 35
Electronic Draft Control “H” Routine 49
Central Controller (XCM) 175 and 190 Models and Front Suspension 120 to 155 Models
H–Routines, includes the following systems:–
Front Suspension, Electronic Engine Control, Electro–Hydraulic Remotes
and Rear PTO 57
Connectors and Harnesses
Full Powershift 175 & 190 Models Chapter 12A
Section Description Page
55 000 Wiring Harnesses 2
Main Connectors 3
Wire Identification and colour coding 4
Lighting Harness 6
Front Main (Engine) Harness 10
Rear Main (Transmission) Harness, 16
Cab Main Harness,25
Electronic Right Hand Console 34
MAIN HARNESS CONNECTORS FROM SERIAL NUMBER ACM263461 ONWARDS Page
Main Connectors 51
Front Main (Engine) Harness 52
Rear Main (Transmission) Harness, 54
Cab Main and Right Hand Console Harnesses, 56
Contents Continued:
xxiii 6045511102 –02–2006
Connectors and Harnesses
Full Powershift 120 to 155 Models Chapter 12B
Section Description Page
55 000 Wiring Harnesses 2
Main Connectors 3
Wire Identification and colour coding 4
Lighting Harness 6
Front Main (Engine) Harness 10
Rear Main (Transmission) Harness 17
Cab Main Harness25
MAIN HARNESS CONNECTORS FROM SERIAL NUMBER ACM262719 ONWARDS Page
Main Connectors 47
Front Main (Engine) Harness 48
Rear Main (Transmission) Harness 50
Cab Main Harness52
Connectors and Harnesses
Semi–Powershift 120 to 155 Models Chapter 12C
Section Description Page
55 000 Wiring Harnesses 2
Main Connectors 3
Wire Identification and colour coding 4
Lighting Harness 6
Front Main (Engine) Harness 10
Rear Main (Transmission) Harness, 17
Cab Main Harness, 25
MAIN HARNESS CONNECTORS FROM SERIAL NUMBER ACM263458 ONWARDS Page
Main Connectors 45
Front Main (Engine) Harness 46
Rear Main (Transmission) Harness, 48
Cab Main Harness, 50
Contents Continued:
6045511102 –02–2006 xxiv
Connectors and Harnesses
Dual Command 120 to 140 Models Chapter 12D
Section Description Page
55 000 Wiring Harnesses 2
Main Connectors 3
Wire Identification and colour coding 4
Lighting Harness 6
Front Main (Engine) Harness 10
Rear Main (Transmission) Harness, 17
Cab Main Harness25
MAIN HARNESS CONNECTORS FROM SERIAL NUMBER ACM262036 ONWARDSPage
Main Connectors 45
Front Main (Engine) Harness 46
Rear Main (Transmission) Harness, 48
Cab Main Harness50
Calibration Procedures Chapter 13
Section Description Page
55 100 Set Up Procedures 1
Power Command (Full Powershift) Transmission Controller Configuration 2
Calibration Error Codes (’U’ Codes) 3
Dual Command Transmission — Clutch and Synchroniser Calibration6
Range Command Transmission — Clutch and Synchroniser Calibration 8
Power Command Transmission — Clutch Calibrations 11
Electronic Draft Control — Calibration of Lift Lever/Arm Potentiometers 14
Electronic Draft Control — Calibration of EDC Valve Solenoids 16
Electronic Management Unit — Ground Speed/Steering Angle Calibration 18
Digital Instrument Cluster — Ground Speed Calibration 19
With Radar / Less Radar connector Selection20
Suspended Front Axle — Suspended Front Axle Calibration 21
Electro–Hydraulic Remote Valve Lever Calibration 23
Electro–Hydraulic Remote Valve Renumbering procedure 24
PTO Torque Sensor Calibration (175 & 190 Models only) 26
PTO Clutch Calibration (175 & 190 Models only) 28
Contents Continued:
xxv 6045511102 –02–2006
Electrical Introduction
Semi–Powershift Models from Serial NoACM265009 Chapter 14A
Section Description Page
55 100 Electrical System and Fuses Description1
Fuses and Relays 4
Controllers 8
Diagnostic Connectors 10
System Precautions For Battery Charging and Welding 11
Temporary Wiring Repair 12
System Diagrams 15
Wiring Diagrams Chapter 14B
Full Powershift (175–190 Models) from Serial No ACM263461
Full Powershift (120–155 Models) from Serial No ACM262719
Semi–Powershift Models from Serial No ACM263458 to ACM265009
Power Shuttle Models from Serial No ACM262036
Mechanical Transmissions Models from Serial No ACM262853
Description Page
Wiring diagram circuit descriptions (All Models) 1
How to use the linear wiring diagrams 2
Symbols 4
Component identification and wiring diagram location key 5
Wiring Diagrams:
Full Power Shift Transmission, 175 to 190 Models 13
Full Power Shift Transmission, 120 to 155 Models 73
Semi Power Shift Transmission, 120 to 155 Models 133
Power Shuttle Transmission, 120 to 140 Models 193
Mechanical Transmission, 120 to 140 Models 253
Wire identification key 313
Wiring Diagrams
Semi–Powershift Models from Serial No ACM265009 Chapter 14C
Description Page
Wiring diagram circuit descriptions (All Models) 1
How to use the linear wiring diagrams 2
Symbols 4
Component identification and wiring diagram location key 5
Wiring Diagrams:
Semi Power Shift Transmission, 120 to 155 Models xx
Wire identification key xxx
Contents Continued:
6045511102 –02–2006 xxvi
Electrical Harnesses
Semi–PowerShift Models From Serial No ACM265009 Chapter 14D
(Processor reduction change) Page
Cab Main Harness,2
Right Hand Console Harness, 14
Diagnostic ’H’ Routines
— Semi–Powershift models from Serial No ACM265009 Chapter 14E
Section Description Page
Introduction 2
Range Command Transmission (F — –) ‘H’ Routine 5
Front Axle Suspension (L — –) ‘H’ Routine 23
Electronic Draft Control (EDC) (H — –) ‘H’ Routine 33
Power Take Off (PTO) (P — –) ‘H’Routine 45
Vistronic Fan (t — –) ‘H’ Routine 53
Fault Codes Chapter 14F
Section Description Page
55 000 Full Power shift (175–190 Models) from Serial No ACM263461
Full Power shift (120–155 Models) from Serial No ACM262719
Semi–Power shift Models from Serial No ACM263458 to ACM265009
Power Shuttle Models from Serial NoACM262036
Mechanical Transmissions Models from Serial No ACM262853 Refer to EST or RM CD
Fault Codes Chapter 14G
Section Description Page
55 000 Semi–Power shift Models from Serial No  Refer to EST or RM CD
CAB SECTION 90
Cab Removal Chapter 1
Section Description Page
Torques 2
Special Tools 2
90 150 Cab Removal and Installation 3
90 150 Suspension Adjustment 11

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