New Holland Tracteurs série TM service manuel

[rgmaster3]

CONTENTS – VOLUME 1
GENERAL SECTION 00
General Instructions and Health and Safety Chapter 1
ENGINE SECTION 10
Separating and Removing The Engine Chapter 1

Torques2
Special Tools . 3
10 100 Separating Front Axle and Front Support from Engine 4
Separating Engine and Front Support from Transmission 14 .
10 100 Engine Removal 21 .
7.5L CNH Engine Chapter 2

10 000 Specifications 2
Greases and Sealants 8
Tightening Torques 10
Special Tools 12
Fault Finding 13
Description and Operation 17
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:
604.55.111.00 –06–2002 ii

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

10 200 Specifications 2
Torques2
Special Tools . 3
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 Check 14
Injection System Bleeding 17
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 Installation 32.
Crankcase Ventilation 32 .
10 220 Foot Throttle Cable – Replacement and Adjustment 33
Hand Throttle Cable – Replacement and Adjustment 33
Contents Continued:
604.55.111.00 –06–2002 iii
CLUTCHES SECTION 18
Clutches Chapter 1

18 000 Specifications 1
Tightening Torques 2
Sectional Views . 3
Special Tools . 4
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

21 000 Specifications 1
Tightening Torques 3
Special Tools . 5
Sectional Views . 9
Description and Operation 12
Pressure Testing 20 .
Calibration 24
Fault Finding see Section 55
21 111 Removal – Installation – Overhaul 27 .
Contents Continued:
604.55.111.00 –06–2002 iv
Power Command 30 and 40 kph Transmission, 120 – 155 Models
(Full Powershift) Chapter 2

21 000 Specifications 2
Tightening Torques 5
Special Tools 10
Transmission Cross Section 13
Description and Operation and Power Flows 16 .
Clutch Calibrations 34
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
Power Command Transmission, 175 – 190 Models
(Full Powershift) Chapter 3

21 000 Specifications 2
Tightening Torques 5
Special Tools . 7
Description 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
21 113 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 .
Contents Continued:
604.55.111.00 –06–2002 v
Dual Command Transmission (HI–LO) Chapter 4

21 000 Specifications 1
Tightening Torques 4
Special Tools . 6
Sectional Views 10
Description and Operation 12
Clutch and Synchroniser Calibration 16 .
Pressure Testing 19 .
Error Codes and fault Finding 22 .
Limp Home 28
21 112 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

21 000 Specifications 2
Tightening Torques 4
Special Tools . 6
Sectional Views 10
Description 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
Contents Continued:
604.55.111.00 –06–2002 vi
DRIVE LINES (FWD ELECTRO–HYDRAULIC CLUTCH) SECTION 23
Drive Lines–Tractors with Dual Command and Shuttle Command
Transmissions Chapter 1

23 000 Specifications 1
Tightening Torques 2
Special Tools . 2
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

23 000 Specifications 2
Tightening Torques 2
Special Tools . 2
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 .
MECHANICAL FRONT AXLE SECTION 25
Mechanical Front Axle Chapter 1

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 .
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
Contents Continued:
604.55.111.00 –06–2002 vii

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

25 000 Specifications 2
Tightening Torques 2
Description and Operation 3.
System Schematics 6
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.
MECHANICAL REAR WHEEL DRIVE (Rear Axle) SECTION 27
Mechanical Rear Wheel Drive (Models 120 – 155) Chapter 1

27 000 Specifications 2
Tightening Torques 4
Special Tools . 6
Sectional Views . 9
Description and Operation 11.
Fault Finding 14
27 100 Rear Axle Housing – Removal and Installation 16.
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 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
Contents Continued:
604.55.111.00 –06–2002 viii
Mechanical Rear Wheel Drive (175–190 Models) Chapter 2

27 000 Specifications 1
Tightening Torques 3
Special Tools . 5
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

31 000 Specifications 1
Tightening Torques 3
Special Tools . 3
Sectional Views . 4
Description and Operation 6.
Hydraulic Flow Diagrams 11
Fault Finding 14
31 100 Removal–Installation–Overhaul 16 .
Ground Speed Interlock Switch Adjustment 27

Rear Power Take–Off, 175–190 Models Chapter 2

31 000 Specifications 2
Tightening Torques 4
Special Tools . 5
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
Contents Continued:
604.55.111.00 –06–2002 ix
Hydraulic Front Lift and Power Take Off Chapter 3

31 000 Specifications 2
Torques2
Description 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 SECTION 33
Tractor Brakes Chapter 1

33 000 Specifications 2
Special Tools . 3
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
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
Contents Continued:
604.55.111.00 –06–2002 x
Pneumatic Trailer Brakes Chapter 2

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 – VOLUME 2
HYDRAULIC SYSTEMS SECTION 35
Introduction Chapter 1

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 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 .
Contents Continued:
604.55.111.00 –06–2002 xi
Variable Flow Hydraulic Pump Assembly
120 to 155 Models Chapter 2

35 000 Special Tools . 1
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 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
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:
604.55.111.00 –06–2002 xii
Variable Flow Hydraulic Pump Assembly
175 to 190 Models Chapter 3

35 000 Special Tools . 2
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 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
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:
604.55.111.00 –06–2002 xiii
Hydraulic Lift Assembly with Electronic Draft Control Chapter 4

35 000 Specifications 2
Special Tools . 2
Tightening Torques 3
Description 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) 41 .
35 134 Disassembly 44
Mechanical Rear Hydraulic Lift Chapter 5

35 000 Specifications 1
Tightening Torques 3
Special Tools . 5
Sectional Views . 6
Description and Operation 9.
Troubleshooting 13
35 114 Removal – Installation – Overhaul 15

Closed Centre Remote Control Valves Chapter 6

35 000 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.
Description 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 18 .
Contents Continued:
604.55.111.00 –06–2002 xiv

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 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
35 204 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 Chapter 7

35 000 Specifications –Tightening Torques 1
Special Tools . 2
Sectional Views . 3
Description and Operation 6.
35 204 Removal – Installation – Overhaul 11
External Lift Rams Chapter 8

120 TO 155 MODELS
35 000 Specifications 2
Sectional Views . 2
Description and Operation 3.
35 116 Removal – Installation – Overhaul 3
Disassembly – Reassembly 3 .
175 AND 190 MODELS
35 000 Specifications 4
Sectional Views . 4
Description and Operation 5.
35 116 Removal – Installation – Overhaul 5
Disassembly – Reassembly 6 .
Contents Continued:
604.55.111.00 –06–2002 xv
Hydraulic Pressure Testing Chapter 9

35 000 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 .
Contents Continued:
604.55.111.00 –06–2002 xvi

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

35 000 Specifications 1
Tightening Torques 3
Special Tools . 4
Sectional Views – Description and Operation 5 .
Troubleshooting see Chapter 5 .
35 104 Removal – Installation – Overhaul 6
Trailer Brake Auxiliary Valves Chapter 11

35 000 Specifications 2
Torques2
Special Tools . 2
Description and Operation 3.
33 220 Italian Trailer Brakes 10.
Pressure Testing 17 .
Hydraulically Adjustable Right Hand Lift
and Top Link Cylinders Chapter 12

35 000 Specifications 1
Sectional Views . 2
Tightening Torques 3
Description and Operation 4.
Removal – Installation – Overhaul 5
STEERING SYSTEMS SECTION 41
Hydrostatic Steering Systems Chapter 1

41 000 Specifications 2
Tightening Torques 3
Special Tools . 3
Description and Operation 4.
Fault Finding . 11
System Testing 12
Contents Continued:
604.55.111.00 –06–2002 xvii

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 – Overhaul 27.
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

44 000 Specifications 1
Tightening Torques 3
Special Tools . 5
Description and Operation 5.
Troubleshooting . 5
Sectional 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 SECTION 50
Air Conditioning Chapter 1

50 000 Specifications 2
Tightening Torques 2
Special Tools . 2
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 .
Contents Continued:
604.55.111.00 –06–2002 xviii
ELECTRICAL SYSTEM SECTION 55
Electrical Introduction Chapter 1

55 100 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) Chapter 2

55 440 Introduction 1
Worklamp Operation 2
Functions controlled by the Electronic Management Unit 2 .
Electronic Management Unit with Terralock . 3
Touch Panels 5
Calibrations 6
Brake Switch Adjustment 7
Removal and Installation 7
Error Codes 8
Contents Continued:
604.55.111.00 –06–2002 xix
Electronic Instrument Cluster Chapter 3

55 100 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

55 100 Introduction 1
Senders and Sensors 5.
Serviceability . 11
Analogue Instrument Cluster Chapter 5

55 100 Introduction 1
Senders, Sensors and Switches 4
Serviceability . 9
Starting System Chapter 6

55 000 Specifications 1
Tightening Torques 1
Description and Operation 2.
Fault Finding . 5
System Testing . 6
55 201 Removal and Installation 8
Overhaul . 8
Bench Tests 11
Contents Continued:
604.55.111.00 –06–2002 xx
Charging System Chapter 7

55 000 Specifications 1
Tightening Torques 1
Description and Operation 2.
Fault Finding . 4
55 301 Removal, Installation and Overhaul 10
Battery Chapter 8

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:
604.55.111.00 –06–2002 xxi
CONTENTS – VOLUME 3 & 4
Fault Codes Chapter 10

55 000 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
Contents Continued:
604.55.111.00 –06–2002 xxii

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

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

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
Contents Continued:
604.55.111.00 –06–2002 xxiii
Connectors and Harnesses
Full Powershift 120 to 155 Models Chapter 12B

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
Connectors and Harnesses
Semi–Powershift 120 to 155 Models Chapter 12C

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.
Connectors and Harnesses
Dual Command 120 to 140 Models Chapter 12D

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
Contents Continued:
604.55.111.00 –06–2002 xxiv
Calibration Procedures Chapter 13

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 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 SECTION 90
Cab Removal Chapter 1

Torques2
Special Tools . 2
90 150 Cab Removal and Installation 3
90 150 Suspension Adjustment 11

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