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

Complete service repair manual with Electrical Wiring Diagrams for New Holland TM120, TM130, TM140, TM155, TM175, TM190, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

New Holland TM Series Tractors (TM120, TM130, TM140, TM155, TM175, TM190 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

604.55.111.00 - TM-Series Tractors (TM120, TM130, TM140, TM155, TM175, TM190) Repair Manual.pdf

PRODUCT DETAILS:
Total Pages: 5,048 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

ONTENTS – VOLUME 1
GENERAL 00
General Instructions and Health and Safety
ENGINE 10
Separating and Removing The Engine
Chapter 1
Torques . . 2
Special Tools . . 3
Separating Front Axle and Front Support from Engine . . 4
Separating Engine and Front Support from Transmission . . 14
Engine Removal . . 21
7.5L CNH Engine Description
10 000 Specifications . . 2
Greases and Sealants . . 8
Tightening Torques . . 10
Special Tools . . 12
Fault Finding . . 13 and Operation . . 17
10 001 Engine Overhaul–Introduction . . 24 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
Injection Pump Timing Check . . 25
10 102 Rear Cover Plate . . 46
10 102 Oil Pump . . 47
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 of Operation . . 68
Troubleshooting . . 70
Specifications . . 71
Overhaul . . 72
Fuel System
Chapter 3 Description
10 200 Specifications . . 2
Torques . . 2
Special Tools . . 3 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 Check . . 14
Injection System Bleeding . . 17
Injection System Testing and Overhaul . . 18
Electric Lift Pump – Removal . . 23
Electric Lift Pump – Testing . . 23
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 Installation . . 32
Crankcase Ventilation . . 32
Foot Throttle Cable – Replacement and Adjustment . . 33
Hand Throttle Cable – Replacement and Adjustment . . 33
CLUTCHES 18
Clutches
Chapter 1
Specifications . . 1
Tightening Torques . . 2al Views . . 3
Special Tools . . 4 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 21
Semi–Powershift Transmission (Range Command)
Chapter 1 Description Specifications . . 1
Tightening Torques . . 3
Special Tools . . 5al Views . . 9 and Operation . . 12
Pressure Testing . . 20
Calibration . . 24
Fault Finding . . see Section 55
Removal – Installation – Overhaul . . 27
tents Continued:
Power Command 30 and 40 kph Transmission, 120 – 155 Models
(Full Powershift)
Specifications . . 2
Tightening Torques . . 5
Special Tools . . 10
Transmission Cross Section . . 13 and Operation and Power Flows . . 16
Clutch Calibrations . . 34
Pressure Testing . . 39
Error Codes and Fault Finding . . 42
Limp Home Tool . . 46 Transmission Removal and Installation . . 47
21 155 Transmission Overhaul – Disassembly . . 53
21 155 Transmission Overhaul – Reassembly . . 78
Power Command Transmission, 175 – 190 Models
(Full Powershift)
Chapter 3
Specifications . . 2
Tightening Torques . . 5
Special Tools . . 7 and Operation . . 10
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
Transmission Housing – Removal and Installation . . 52
21 155 Transmission Disassembly . . 59
21 155 Oil Manifold Bushes, Removal and Installation . . 72
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 Reassembly . . 88
21 155 Output Shaft End Flow Adjustment . . 96
21 155 Medium Shaft End Float Adjustment . . 97
Dual Command Transmission (HI–LO)
Chapter 4
Specifications . . 1
Tightening Torques . . 4
Special Tools . . 6al Views . . 10 and Operation . . 12
Clutch and Synchroniser Calibration . . 16
Pressure Testing . . 19
Error Codes and fault Finding . . 22
Limp Home . . 28
Transmission Removal and Installation . . 29
Transmission Overhaul . . 32
Shuttle Gear Bearing Adjustment . . 46
Range Input and Output Shaft Bearing Adjustment . . 48
21 134 HI LO Transmission Valve – Overhaul . . 51
21 134 HI LO Transmission Control Assembly . . 54
Shuttle Command (Mechanical Transmission)
Chapter 5 Description Specifications . . 2
Tightening Torques . . 4
Special Tools . . 6al Views . . 10 and Operation . . 14
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
Dual Command Transmission (HI–LO)
Chapter 4
Specifications . . 1
Tightening Torques . . 4
Special Tools . . 6al Views . . 10 and Operation . . 12
Clutch and Synchroniser Calibration . . 16
Pressure Testing . . 19
Error Codes and fault Finding . . 22
Limp Home . . 28
Transmission Removal and Installation . . 29
Transmission Overhaul . . 32
Shuttle Gear Bearing Adjustment . . 46
Range Input and Output Shaft Bearing Adjustment . . 48
21 134 HI LO Transmission Valve – Overhaul . . 51
21 134 HI LO Transmission Control Assembly . . 54
Shuttle Command (Mechanical Transmission)
Chapter 5 Description Specifications . . 2
Tightening Torques . . 4
Special Tools . . 6al Views . . 10 and Operation . . 14
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 ) 23
Drive Lines–Tractors with Dual Command and Shuttle Command
Transmissions
Chapter 1
Specifications . . 1
Tightening Torques . . 2
Special Tools . . 2al Views . . 4 and Operation . . 5
Troubleshooting . . 5
Hydraulic Flow Diagrams . . 6
Removal–Installation–Overhaul . . 8
Drive Lines–Tractors with Range Command and
Power Command ( Full Powershift) Transmissions
Specifications . . 2
Tightening Torques . . 2
Special Tools . . 2al Views . . 3
Troubleshooting . . 4 and Operation . . 5
Hydraulic Flow Diagrams . . 6 Drive shaft Removal–Installation . . 8
23 202 Electro Hydraulic Clutch Removal–Installation–Overhaul . . 9
MECHANICAL FRONT AXLE 25
Mechanical Front Axle
Chapter 1
Specifications . . 1
Tightening Torques . . 2
Special Tools . . 4al Views . . 7 and Operation . . 8
Troubleshooting . . 11
Standard Axle – Removal/Installation . . 12
Suspended Axle – Removal/Installation . . 15
Supersteer 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
DRIVE LINES ( FWD ELECTRO–HYDRAULIC CLUTCH ) 23
Drive Lines–Tractors with Dual Command and Shuttle Command
Transmissions
Chapter 1
Specifications . . 1
Tightening Torques . . 2
Special Tools . . 2al Views . . 4 and Operation . . 5
Troubleshooting . . 5
Hydraulic Flow Diagrams . . 6
Removal–Installation–Overhaul . . 8
Drive Lines–Tractors with Range Command and
Power Command ( Full Powershift) Transmissions
Specifications . . 2
Tightening Torques . . 2
Special Tools . . 2al Views . . 3
Troubleshooting . . 4 and Operation . . 5
Hydraulic Flow Diagrams . . 6 Drive shaft Removal–Installation . . 8
23 202 Electro Hydraulic Clutch Removal–Installation–Overhaul . . 9
MECHANICAL FRONT AXLE 25
Mechanical Front Axle
Chapter 1
Specifications . . 1
Tightening Torques . . 2
Special Tools . . 4al Views . . 7 and Operation . . 8
Troubleshooting . . 11
Standard Axle – Removal/Installation . . 12
Suspended Axle – Removal/Installation . . 15
Supersteer 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
604.55.111.00 –06–2002
viContents Continued:
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) Description Specifications . . 2
Tightening Torques . . 2 and Operation . . 3
System Schematics . . 6
Suspended Front Axle Calibration Procedure . . 18
Error Code Listing . . 20 Suspended Front Axle Assembly–Removal and Installation . . 22 Suspension Cylinder Removal and Overhaul . . 30
Suspension Control Valve Assembly–Removal . . 34
Suspension Control Valve Assembly–Overhaul . . 35
MECHANICAL REAR WHEEL DRIVE (Rear Axle)
Mechanical Rear Wheel Drive (Models 120 – 155)
Chapter 1
Specifications . . 2
Tightening Torques . . 4
Special Tools . . 6al Views . . 9 and Operation . . 11
Fault Finding . . 14 Rear Axle Housing – Removal and Installation . . 16 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 Installation . . 40
27 110 Hydraulic Differential Lock Control Unit – Dog Type Clutch . . 44
27 110 Hydraulic Differential Lock Control Unit – Multi Plate Clutch . . 46
27 120 Final Drive Case – Removal and Installation . . 47
27 120 Drive Wheel Shaft – Removal and Installation . . 51
604.55.111.00 –06–2002Contents Continued:
Mechanical Rear Wheel Drive (175–190 Models)
Specifications . . 1
Tightening Torques . . 3
Special Tools . . 5al Views . . 7 and Operation . . 9
Troubleshooting . . 11
Removal – Installation – Overhaul . . 13
Rear Axle Adjustments . . 28
Hydraulic Differential Lock Control . . 36
Drive Wheel Shaft – Removal– Installation . . 49
POWER TAKE–OFF 31
Rear Power Take–Off, 120–155 Models
Chapter 1 Description Specifications . . 1
Tightening Torques . . 3
Special Tools . . 3al Views . . 4 and Operation . . 6
Hydraulic Flow Diagrams . . 11
Fault Finding . . 14
Removal–Installation–Overhaul . . 16
Ground Speed Interlock Switch Adjustment . . 27
Rear Power Take–Off, 175–190 Models Description Specifications . . 2
Tightening Torques . . 4
Special Tools . . 5al Views . . 6 and Operation . . 8
Hydraulic Operation of Power Take Off (PTO) . . 12
Fault Finding . . 18
Removal–Installation–Overhaul . . 20
Calibration . . 29
604.55.111.00 –06–2002iContents Continued:
Hydraulic Front Lift and Power Take Off
Chapter 3
Specifications . . 2
Torques . . 2 and Operation
35 162 Front Hydraulic Lift. . 3
31 146 Front P.T.O. . 5
Fault Finding . . 10
Overhaul
35 162 Front Hydraulic Lift . . 11
31 142 Front P.T.O.. . 16
Hydraulic and Electrical Connections . . 24
BRAKING SYSTEM 33
Tractor Brakes
Chapter 1 Description
33 000 Specifications . . 2
Special Tools . . 3
Tightening Torques . . 5al Views . . 5 and Operation . . 8
Operation, Power Brake Coloured Diagrams . . 11
Fault Finding . . 15
Tasks Before Carrying Out Brake Overhaul . . 17
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 Cylinder . . 32
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
604.55.111.00 –06–2002Contents Continued:
Pneumatic Trailer Brakes Description
33 000 Specifications . . 1
Tightening Torques . . 2 and Operation . . 3
Fault Finding . . 13
33 000 Removal and Installation . . 15
33 000 Overhaul . . 20
Pressure Testing . . 30
CONTENTS – VOLUME 2
HYDRAULIC SYSTEMS SECTION 35
Introduction Chapter 1
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 Check . . 54
Transmission Low Pressure Warning Light ‘ON’ . . 55
Charge Pressure Light . . 56
Intake Filter Restriction Warning Light . . 56
Power Steering . . 57
Trailer Brakes . . 57
Hydraulic Lift . . 58
Remote Control Valves . . 59
604.55.111.00 –06–2002
xContents Continued:
Variable Flow Hydraulic Pump Assembly
120 to 155 Models Description Special Tools . . 1
Specifications . . 2
Tightening Torques . . 3 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 Check . . 19
Transmission Low Pressure Warning Light ‘ON’ . . 21
Charge Pressure Light . . 23
Intake Filter Restriction Warning Light . . 23
Power Steering . . 24
Trailer Brakes . . 24
Hydraulic Lift . . 25
Remote Control Valves . . 26
Pump Pressure and Flow Testing . . 27
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 Test . . 32
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
604.55.111.00 –06–2002Contents Continued:
Variable Flow Hydraulic Pump Assembly
175 to 190 Models
Chapter 3 Description Special Tools . . 2
Specifications . . 3
Tightening Torques . . 4 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 Check . . 29
Transmission Low Pressure Warning Light ‘ON’ . . 30
Charge Pressure Light . . 31
Intake Filter Restriction Warning Light . . 31
Power Steering . . 32
Trailer Brakes . . 32
Hydraulic Lift . . 33
Remote Control Valves . . 34
Pump Pressure and Flow Testing . . 36
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 Test . . 41
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
604.55.111.00 –06–2002iContents Continued:
Hydraulic Lift Assembly with Electronic Draft Control
Chapter 4
Specifications . . 2
Special Tools . . 2
Tightening Torques . . 3 and Operation . . 4
Principal of Draft Control . . 4
Components . . 7
Operation of Draft Control . . 13
Hydraulic Operation of Lift Control Valve . . 16
Trouble Shooting and Calibration . . 24
Overhaul
35 138 Electronic Draft Control Valve – Removal and Installation . . 33
35 138 Disassembly . . 35
35 130 Load Sensing Pin Replacement . . 40
35 134 Hydraulic Lift Cover – Removal and Installation (120 to 155 Models Only)
35 134 Disassembly . . 44
Mechanical Rear Hydraulic Lift
Chapter 5 Description Specifications . . 1
Tightening Torques . . 3
Special Tools . . 5al Views . . 6 and Operation . . 9
Troubleshooting . . 13
35 114 Removal – Installation – Overhaul . . 15 Description
Closed Centre Remote Control Valves
Chapter 6
Special Tools . . 2
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 list . . 6 and Operation – Mechanical Remote Valves . . 7
Oil Flow In Neutral . . 12
Oil Flow in Raising (Cylinder Extend) . . 14
Oil Flow in Lowering (Cylinder Retract) . . 16
Oil Flow in Float . . 18ii
604.55.111.00 –06–2002Contents Continued:
Operation of Detent Pressure Regulating Valve . . 20
Operation of Two or More Control Valves Simultaneously . . 23 and Operation – Electro–Hydraulic Remote Valves . . 25
Re–Calibrating Remote Valve Levers . . 34
Oil Flow In Neutral . . 40
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
Overhaul – Mechanical Remote Valves . . 51
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 Disassembly . . 68
Open Centre Remote Control Valves
Specifications –Tightening Torques
Special Tools . . 2al Views . . 3 and Operation . . 6
Removal – Installation – Overhaul . . 11
External Lift Rams
120 TO 155 MODELS
Specifications . . 2al Views . . 2 and Operation . . 3
Removal – Installation – Overhaul . . 3
Disassembly – Reassembly . . 3
175 AND 190 MODELS
Specifications . . 4al Views . . 4 and Operation . . 5
Removal – Installation – Overhaul . . 5
Disassembly – Reassembly . . 6
604.55.111.00 –06–2002vContents Continued:
Hydraulic Pressure Testing
Chapter 9 Description Introduction . . 3
Special Tools . . 4
Specifications . . 5
Variable Displacement Hydraulic Pump Installation . . 6
Open Centre Hydraulic Pump Installation . . 8
Fault Finding . . 8
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 Testing . . 18
Low Pressure Standby . . 18
High Pressure Standby . . 19
Lift Ram Pressure Test . . 20
Load Sensing Circuit Test . . 21
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 Test . . 26
Open Centre Lift Pressure Regulating Valve . . 29
Power Command Transmission Clutch Pressure Test . . 30
Range Command Transmission Clutch Pressure Test . . 34
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 Test . . 43
604.55.111.00 –06–2002Contents Continued:
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
Specifications . . 1
Tightening Torques . . 3
Special Tools . . 4al Views – Description and Operation . . 5
Troubleshooting . . see Chapter 5
Removal – Installation – Overhaul . . 6
Trailer Brake Auxiliary Valves
Chapter 11 Description Specifications . . 2
Torques . . 2
Special Tools . . 2 and Operation . . 3
Italian Trailer Brakes . . 10
Pressure Testing . . 17
Hydraulically Adjustable Right Hand Lift
and Top Link Cylinders
Chapter 12
Specifications . . 1al Views . . 2
Tightening Torques . . 3 and Operation . . 4
Removal – Installation – Overhaul . . 5
STEERING SYSTEMS 41
Hydrostatic Steering Systems
Chapter 1
Specifications . . 2
Tightening Torques . . 3
Special Tools . . 3 and Operation . . 4
Fault Finding . . 11
System Testing . . 12
604.55.111.00 –06–2002iContents Continued:
Steering Motor – Removal and Installation . . 14
Steering Motor Overhaul . . 16
Steering Column – Removal and installation . . 24
Two Wheel Drive Steering Cylinder – Removal and Installation . . 26
Two Wheel Drive Steering Cylinder – Overhaul . . 27
Four Wheel Drive Steering Cylinder – Removal and Installation . . 28
Four Wheel Drive Steering Cylinder – Overhaul . . 29
FRONT AXLE 44
Front Axle and Wheels
Chapter 1
Specifications . . 1
Tightening Torques . . 3
Special Tools . . 5 and Operation . . 5
Troubleshooting . . 5al Views . . 6
44 101 Removal – Installation – Overhaul . . 9
44 511 Front Wheel Camber and Toe–in (Standard Duty Axle) . . 20
Front Wheel Camber and Toe–in (Heavy Duty Axle) . . 23
AUXILIARY UNITS 50
Air Conditioning
Chapter 1
Specifications . . 2
Tightening Torques . . 2
Special Tools . . 2
Safety Precautions . . 2 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 . . 44ii
604.55.111.00 –06–2002Contents Continued:
ELECTRICAL SYSTEM 55
Electrical Introduction
Chapter 1
Electrical System and Fuses Description . . 1
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
Electronic Management Unit (EMU)
Introduction . . 1
Worklamp Operation . . 2
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
604.55.111.00 –06–2002iiiContents Continued:
Electronic Instrument Cluster
Chapter 3
Introduction . . 2
Senders and Sensors . . 9
Programming Central LCD . . 21
Programming Performance Monitor . . 23
Serviceability . . 25
Fault Codes . . 26
Diagnostic Memory . . 27
Instrument Panel Byte Level Set–up . . 28
Software Revision Level Check . . 29
Analogue Electronic Instrument Cluster
Chapter 4
Introduction . . 1
Senders and Sensors . . 5
Serviceability . . 11
Analogue Instrument Cluster
Chapter 5
Introduction . . 1
Senders, Sensors and Switches . . 4
Serviceability . . 9
Starting System
Chapter 6 Description Specifications . . 1
Tightening Torques . . 1 and Operation . . 2
Fault Finding . . 5
System Testing . . 6
Removal and Installation . . 8
Overhaul . . 8
Bench Tests . . 11x
604.55.111.00 –06–2002Contents Continued:
Charging System Description Specifications . . 1
Tightening Torques . . 1 and Operation . . 2
Fault Finding . . 4
Removal, Installation and Overhaul . . 10
Battery Description Specifications . . 1 and Operation . . 1
Removal and Installation . . 2
Battery Maintenance and Testing . . 3
Battery Charging . . 4
Common Causes of Battery Failure . . 7
Wiring Diagrams
Chapter 9
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
604.55.111.00 –06–2002
xxContents Continued:
CONTENTS – VOLUME 3 & 4
Fault Codes
Chapter 10 Description Introduction . . 3
Special Tools . . 4
Wiring Harness Repairs . . 4
Digital Multi–Meter – Basic Operation . . 7
Electrical Test Procedures . . 10
Circuit Components – Basic Description . . 13
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
xxi
604.55.111.00 –06–2002Contents Continued:
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
Diagnostic ’H’ Routines
Chapter 11
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
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
604.55.111.00 –06–2002
xxiiContents Continued:
Connectors and Harnesses
Full Powershift 120 to 155 Models
Chapter 12B
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
Connectors and Harnesses
Semi–Powershift 120 to 155 Models
Chapter 12C
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
Connectors and Harnesses
Dual Command 120 to 140 Models
Chapter 12D
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
604.55.111.00 –06–2002Contents Continued:
Calibration Procedures
Chapter 13
Set Up Procedures . . 1
Power Command (Full Powershift) Transmission Controller Configuration . . 2
Calibration Error Codes (’U’ Codes) . . 3
Dual Command Transmission – Clutch and Synchroniser Calibration . . 6
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 Selection . . 20
Suspended Front Axle – Suspended Front Axle Calibration . . 21
Electro–Hydraulic Remote Valve Lever Calibration . . 23
Electro–Hydraulic Remote Valve Renumbering procedure . . 24
P.T.O. Torque Sensor Calibration (175 & 190 Models only) . . 26
P.T.O. Clutch Calibration (175 & 190 Models only) . . 28
CAB 90
Cab Removal
Torques . . 2
Special Tools . . 2
90 150 Cab Removal and Installation . . 3
90 150 Suspension Adjustment . . 11

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