Part of the New Holland Repair Manuals.
This is New Holland service manual 51543580, 1st edition, November 2018. It covers the PowerStar 90, 100, 110 and 120 Tier 4B (final) tractors for North America. The cover reads PIN ELRT5100PJLE50082 and above.
It covers cab and platform tractors with Mechanical or Power Shuttle transmissions. It runs from SCR and EGR through the clutch, creeper, 4WD, axles, PTO, hydraulics and three-point hitch. Cab air, electrical schematics and fault codes are in it too.
The specifications give the hydraulic relief, steering, Power Shuttle and PTO clutch pressures, PTO engine speeds and fill capacities, and troubleshooting tables cover steering, cab heating and air conditioning.
What's Inside This New Holland PowerStar 90, PowerStar 100, PowerStar 110, PowerStar 120 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction, Consumables and Identification | 1-40 | Variants, PIN and Engine Table, Safety Rules, Engine Coolant, Hydraulic Fitting Torques, Front Loader Specifications, Consumables, Identification Plates |
| Engine Removal, Fuel and Air Intake | 41-141 | Crankcase Torques, Engine Removal and Installation, Oil and Filter, Fuel Tanks, Fuel Filters, Heater and Water Separator, Air Lines and Air Filter, Exhaust Pipes |
| Exhaust Aftertreatment (SCR) | 142-257 | Muffler Catalyst, AdBlue Supply Module, AdBlue Tank, Coolant Valve, Lines, System Check |
| EGR, Cooling System and Intercooler | 258-336 | Exhaust Gas Recirculation, Radiator, Coolant Drain and Fill, Expansion Tank, Pipes and Hoses, Fan and Drive Belt, Intercooler, Crankcase Breather |
| Main Clutch and PTO Clutch | 337-400 | Main Clutch and PTO Clutch Controls, Torques and Sections, Assembly and Removal, Slip Clutch |
| Mechanical Transmission and Power Shuttle | 401-589 | Specifications, External Levers, Hydraulic Components, Gearbox Casing, Main Clutch Housing, Power Shuttle Controls, Hydraulic Schematic, Control Valve, Filters and Lines |
| Creeper, Reverser and 4WD | 590-728 | Creeper, Reverser, Transmission Cooler, Drive Housing, 4WD Electro-Hydraulic Control, Valves and Hydraulic Schematics, Drive Shaft |
| Front Axle | 729-936 | 4WD Front Axle, Non-Driven Axle, Final Drives, Differential, Hubs, King Pins |
| Rear Axle and Power Take-Off | 937-1174 | Bevel Gear, Differential and Lock, Final Drives, Mechanical and Electro-Hydraulic PTO Controls, Single-Speed and Two-Speed PTO |
| Brakes and Hydraulic Systems | 1175-1358 | Brake Pedals, Master Cylinders, Parking Brake, Pumps, Remote Control Valves, Lift Filters, Hitch Control Valve, Lift Cylinder |
| Three-Point Hitch, Steering and Wheels | 1359-1566 | Rear Three-Point Hitch, Lift-O-Matic, Links and Stabilizers, Steering Wheel, Power Steering, Pressure Check, Troubleshooting, Wheels |
| Cab Heating and Air Conditioning | 1567-1756 | Heating and Troubleshooting, Cab Air Ducts and Filters, Air Conditioning Specifications, Pressure Tests, Compressor, Condenser, Evaporator |
| Connector Identification and Component Diagrams | 1757-2198 | Connector Identification, Component Locations, Component Diagrams 00 to 95 |
| Fuses, Relays and Electrical Schematics | 2199-2459 | Fuse and Relay Boxes, How to Use the Wiring Diagrams, Electrical Schematic Sheets 03 to 45, Component Descriptions, Replacement and Measurements |
| Engine Electrics and SCR Electrics | 2460-2739 | Engine Control and ECU, Starter, Alternator, Battery, Fuel and Air Sensors, SCR Supply Modules, NOx and NH3 Sensors, Electronic Modules |
| Transmission, Cab and Lighting Electrics | 2740-2955 | Transmission Control, Radio, Climate Panel and Blower, Hitch Control, Wipers, Lighting |
| Fault Codes: Hitch, Modules and Transmission | 2956-3130 | Fault Code List, EFH Hitch Codes 11 to 38, XCM and CCU Module Codes, Transmission Codes |
| Fault Codes: Engine ECU | 3131-3365 | Engine ECU Fault Codes 3001 to 3838 |
| Fault Codes: PTO, 4WD and Differential Lock | 3366-3454 | Codes 5003 and Up for PTO, 4WD and Differential Lock |
| Fault Codes: CAN, EGR and SCR | 3455-3796 | Codes 17195 to 19999 for CAN Bus, EGR, SCR, DEF and NOx, Fault Code Index |
| Front Loader and Accessories | 3797-3822 | Front Loader, Tool Box |
| Cab and Bodywork | 3823-3999 | Cab Mounts, Roof, Panels, Headliner, Seats, Doors, Glass |
| Platform, Seats, Hood and Decals | 4000-4205 | Platform Without Cab, Operator Seat and Suspension, Hood, Side Panels, Fenders, Decals |
| Special Tool Index | 4206-4211 | Special Tools with References to the Subsections |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine cooling system | 16.0 L (3.5 UK gal) models with cab; 14.0 L (3.1 UK gal) model without cab | p. 281 |
| DEF (AdBlue) tank capacity | 14 L minimum | p. 178 |
| Engine oil | 10W-40 MAT3521 API CJ-4 | p. 33 |
| Drive line oil | 10W - 30 | p. 33 |
| Gearbox oil drained before PTO removal | 48.0 l (12.7 US gal) single-speed mechanical PTO; 58.0 l (15.3 US gal) single-speed hydraulic PTO | p. 1083 |
| Main clutch type | 12”/12” single disk, dry plate dual clutch unit | p. 374 |
| Mechanical transmission | 4-speed constant mesh, synchronized on all gears; 3 ranges for a total of 12 gears | p. 406 |
| Power Shuttle and services working pressure | 17.50 - 18.50 Kg/cm² (248.91 - 263.13 psi) | p. 477 |
| Engine speed for 540 RPM PTO | 1938 RPM single-speed PTO; 1957 RPM two-speed PTO | p. 1071 |
| Engine speed for 1000 RPM PTO | 2125 RPM | p. 1134 |
| PTO clutch working pressure | 17.5 - 18.5 Kg/cm² (248.9 - 263.1 psi) | p. 1072 |
| Remote valve pressure relief setting | 190 - 195 bar (2755 - 2828 psi) | p. 1265 |
| Remote valve detent release pressure | 165.0 - 175.0 bar (2392.5 - 2537.5 psi) | p. 1301 |
| Steering pressure check | 186 bar (2697.00 psi) for all models | p. 1518 |
| Parking brake inner retaining screws torque | 48 N·m (35.40 lb ft) | p. 1202 |
| Battery | 12 V; 800 A cold start; 143 A·h | p. 2524 |
| Air conditioning refrigerant R134A | 650 g (22.9 oz) | p. 1654 |
| Air conditioning system pressures | 16 - 24 bar (232 - 348 psi) delivery side; 0.5 - 3 bar (7.25 - 43.50 psi) suction side | p. 1654 |
New Holland PowerStar 90, PowerStar 100, PowerStar 110, PowerStar 120 Common Problems This Manual Covers
Hard steering
Start at the hydraulic pump and repair it if it is faulty. Foreign bodies can hold the check valve open, or its ball can be missing. Remove the debris, clean the filter and fit a new ball. Calibrate pressure relief valve (22) if it is set wrong. Clean the filter if the relief valve is jammed. Free the steering column if it binds in its bushing. The pressure check reads around 186 bar (2697.00 psi) on all models.
Manual Section: Three-Point Hitch, Steering and Wheels p. 1524Hot air does not come out of the adjustable vents, or it is not hot (cab models)
First check that the ventilation solenoid valves are getting power. Loose connectors or a faulty fan switch can cut it, so check the connections and replace bad parts. Next look for low coolant in the heater radiator, then check the cooling system and find the leak. A faulty heater control valve gets overhauled or replaced. A faulty valve motor gets replaced.
Manual Section: Cab Heating and Air Conditioning p. 1620Code 2011: clutch pedal potentiometer voltage too low (CCU, Power Shuttle)
The transmission disengages while driving and comes back with the reverser lever. The cause is a short to ground or an open circuit between the clutch pedal potentiometer and the CCU, or a failed potentiometer. Check it in H9 mode, channel 48. As you press the pedal, the reading should change smoothly within 220 to 4840 mV. Then check connectors X-322, X-230, X-200 and X-210.
Manual Section: Fault Codes: Hitch, Modules and Transmission p. 3036Code 3773 (DTC 2838): turbocharger boost pressure lower than expected (ECU)
This code sets between 1000 and 4000 engine RPM with coolant above 44.96 °C (112.9 °F). Common causes are a clogged air filter or intake, damaged turbocharger hoses, or a faulty actuator or turbocharger. Inspect the air cleaner and filter first, then the intake and hoses. Check the turbocharger blades and actuator last.
Manual Section: Fault Codes: Engine ECU p. 3338Frequently Asked Questions
Does this manual cover my New Holland PowerStar 90, 100, 110 or 120 tractor?
It covers the PowerStar 90, 100, 110 and 120 Tier 4B (final) tractors for North America, with or without cab, with Mechanical or Power Shuttle transmission. This is service manual 51543580, 1st edition, English, November 2018. The cover reads PIN ELRT5100PJLE50082 and above, but the title page lists a separate starting PIN for each variant, so check your plate against it. The listed engines are F5GFL413J*C006 (90), F5GFL413H*C006 (100), F5GFL413G*C006 (110) and F5GFL413F*C011 (120). p. 1
What are the New Holland PowerStar 90-120 fluid capacities and oil grades?
The engine cooling system holds 16.0 L (3.5 UK gal) on cab models and 14.0 L (3.1 UK gal) without a cab. The DEF (AdBlue) tank is 14 L minimum. Engine oil is 10W-40 MAT3521 API CJ-4, and drive line oil is SAE 10W-30. When the PTO comes out, the book drains 48.0 l (12.7 US gal) from the gearbox with the single-speed mechanical PTO. With the single-speed hydraulic PTO it is 58.0 l (15.3 US gal). p. 281
What engine speed gives 540 and 1000 RPM at the PowerStar PTO?
On the single-speed PTO, 540 RPM comes at 1938 engine RPM. On the two-speed PTO, 540 RPM comes at 1957 engine RPM and 1000 RPM at 2125 engine RPM. The PTO clutch working pressure is 17.5 to 18.5 Kg/cm² (248.9 to 263.1 psi). p. 1071
What are the New Holland PowerStar 90-120 hydraulic, steering and Power Shuttle pressures?
The remote valve pressure relief setting is 190 to 195 bar (2755 to 2828 psi). Detent release is 165.0 to 175.0 bar (2392.5 to 2537.5 psi). The steering pressure check should read around 186 bar (2697.00 psi) on all models. Power Shuttle and services working pressure is 17.50 to 18.50 Kg/cm² (248.91 to 263.13 psi). p. 1265
What is inside this manual: wiring diagrams, fault codes, troubleshooting, engine overhaul?
You get electrical schematic sheets for cab and platform versions, connector component diagrams 00 to 95, fuse and relay boxes, and ECU and module descriptions. The FAULT CODES section lists codes 11 to 19999, each with cause, possible failure modes and solution, plus an index. Troubleshooting tables cover steering, cab heating and air conditioning. Clutch disassembly and assembly is included. There is no engine overhaul. The engine chapter covers torques, removal and installation, oil and filter, fuel, air, exhaust, SCR, EGR and cooling. p. 2959
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