Part of the New Holland Repair Manuals.
The powershift transmission chapter covers the external controls, internal components, torque converter and cooler lines, plus the Carraro TCH90 SD system pressure of 16 bar ± 2 bar. From there it moves on to the axles, brakes, pumps, main control valve, pilot system, steering, telescopic arm and cab.
This is New Holland service manual 51546942, in English, dated October 2018. It covers the TH6.32, TH6.36, TH7.32, TH7.37, TH7.42 and TH9.35 Stage IV telescopic handlers in Standard, S, PLUS and ELITE versions for Europe. It does not cover engine overhaul. For that, it sends you to the engine service manual.
The electrical chapter has separate schematic sets for Standard, S and PLUS machines and for ELITE machines. The fault codes chapter gives each ECU, TCU and UCM code its own entry with cause and solution.
What's Inside This New Holland TH6.32–TH9.35 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| Model List, Engine Codes and Contents | 1-7 | Product, Market, Link Product, Engine, Contents |
| Introduction, Safety, Torque Tables and Capacities | 8-61 | Safety, Basic Instructions, Torque, Consumables, Capacity, Dimensions |
| Engine, Fuel Tank, Fuel Filters and Air Cleaner | 62-115 | Engine and Crankcase, Fuel Tanks, Fuel Filters, Air Cleaners |
| SCR Exhaust Treatment, Engine Cooling and Fan | 116-177 | SCR Exhaust Treatment, Engine Cooling System, Fan and Drive |
| Powershift Transmission and Controls | 178-337 | Powershift Transmission, External Controls, Internal Components |
| Gearbox, Transmission Cooler and Torque Converter | 338-383 | Gearbox, Transmission Cooler and Lines, Torque Converter |
| Four-Wheel Drive System | 384-401 | Drive Shaft |
| Front Axle | 402-493 | Powered Front Axle, Bevel Gear Set, Differential, Final Drive Hub, Steering Knuckles |
| Rear Axle | 494-561 | Powered Rear Axle, Bevel Gear Set, Differential, Planetary and Final Drives |
| Brakes and Controls | 562-655 | Hydraulic Service Brakes, Parking Brake, Trailer Brake, Front Axle Brake |
| Hydraulic Systems, Pumps, Main Control Valve and Pilot System | 656-731 | Hydraulic Schema, Fixed Displacement Pump, Variable Displacement Pump, Main Control Valve, Pilot System |
| Fan Drive, Lift, Boom, Quick Coupler and Telescopic Arm Hydraulics | 732-939 | Auxiliary Hydraulic Function, Hydraulic Fan Drive, Main Lift System, Boom Hydraulic System, Tool Quick Coupler, Telescopic Arm |
| Steering | 940-991 | Steering Control, Hydraulic Control Components, Cylinders |
| Cab Climate Control | 992-1059 | Air Conditioning, Refrigerant, Troubleshooting |
| Electrical Systems, Harnesses and Components | 1060-1154 | Harnesses and Connectors, Fuse, Relay, Sensor |
| Electrical Schematics, Standard, S and Plus Models | 1155-1218 | Electrical Schematic, Starting Circuit, Transmission Solenoid Valves, Core Engine |
| Electrical Schematics, Elite Models | 1219-1281 | Electrical Schematic, Starting Circuit, Transmission Solenoid Valves |
| Engine Schematics, Ground Cable and Connectors | 1282-1885 | Circuit Color Index, Engine Schematics, Fuel Injection, Ground Cable, Connector |
| Starting System, Battery and SCR Electrical System | 1886-1945 | Engine Starting System, Battery, SCR Electrical System |
| Steering Control System and SAR Calibration | 1946-1989 | Steering Control System, Warning Indicators, Calibration |
| Fault Codes | 1990-3135 | Battery Voltage, DEF/AdBlue, Side Drive Transmission, Possible Failure Modes, Solution |
| Telescopic Single Arm | 3136-3153 | Telescopic Arm, Boom Pads |
| Cab, Engine Hood, Panels and Guards | 3154-3203 | Cab, Engine Hood and Panels, Machine Shields and Guards |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Engine type codes | F4HFE413Z*B002 (89 kW) / F4HFE4149*B001 (96 kW, ELITE) | p. 3 |
| Engine displacement, bore x stroke | 4.5 l (274.6 in³); 104 mm x 132 mm | p. 66 |
| Peak torque, Standard/Classic/Plus / Elite | 549 N·m (404.9 lb ft) / 591 N·m (435.9 lb ft) at 1500 RPM | p. 66 |
| Engine oil, with filter change | 12 l (3.2 US gal) | p. 43 |
| Cooling system capacity | 21 L (5.5 US gal) | p. 43 |
| Fuel tank | 138 L (36.5 US gal) | p. 43 |
| DEF/AdBlue tank | 32 l (8.4 US gal) | p. 43 |
| Hydraulic system total capacity | 157 L (41.5 US gal) | p. 43 |
| Transmission oil, total system | 21.45 L (5.67 US gal) | p. 43 |
| Front and rear axle oil | 8 L (2.1 US gal); wheel reduction gear (each) 0.8 L (0.2 US gal) | p. 43 |
| Transmission system pressure (Carraro TCH90 SD) | 16 bar ± 2 bar | p. 183 |
| Wheel nut torque | 800 N·m (590 lb ft) | p. 521 |
| Max hydraulic brake oil pressure | 80 bar (1160 psi) | p. 566 |
| Steering relief valve setting | 170 - 178 bar (2465 - 2581 psi) | p. 944 |
| Steering shock valve setting | 240 bar (3480 psi) ± 5 bar (72 psi) | p. 944 |
| Steering unit capacity | 250 cm³/rev | p. 944 |
| Variable displacement pump cut-off pressure | 260 bar (3770 psi) | p. 686 |
| Boom lift cylinder bore / rod | 140 mm (5.5 in) / 70 mm (2.8 in) | p. 795 |
| A/C refrigerant charge | 1150 g HFC R134A | p. 998 |
| Tires | Standard 460/70R24, optional 500/70R24 | p. 944 |
New Holland TH6.32–TH9.35 Series Common Problems This Manual Covers
Fault 4449 - (DTC 1161): battery voltage is higher than expected [ECU]
The ECU sets this fault when battery voltage goes above 16.1 V. The likely causes are a faulty charging system or the ECU A-9000 software. Check the charging system first and repair it if it is not working properly. If charging is fine, check the ECU A-9000 for the right software and re-flash it if needed.
Manual Section: Fault Codes p. 2020Fault 127-1: Side Drive Transmission Kprop pressure fail [TCU]
This sets when the engine is running and the Kprop Solenoid Valve is energized, but no pressure is detected for more than 10 s. Causes include line pressure under 10 bar, an internal failure in Kprop valve Y-003, or a TCU A-007 fault. Check line pressure, look for leaks in the pressure lines and make sure the Kprop valve is not stuck closed. Then replace Y-003. If the fault stays, load the TCU software or replace TCU A-007.
Manual Section: Fault Codes p. 2179Fault 6730 - (DTC 1A4A): DEF/AdBlue over pressure failure [ECU]
This sets when DEF/AdBlue pressure goes above 11.00 bar (159.50 psi) and does not drop below 10.75 bar (155.88 psi) within 60 s. Check the DEF/AdBlue pressure line or back flow line (tube) for blockage or damage. Repair or replace it as needed. Then run the SCR Fault Repair Verification Test to confirm the fix.
Manual Section: Fault Codes p. 2087Cab air conditioning fan motor or compressor does not work
Use the air conditioning troubleshooting table. If the fan motor is dead, the likely cause is a blown fuse. Check the air conditioning system fuse and replace it if necessary. If the compressor does not work, the compressor belt may be too slack. Adjust the tension of the compressor belt.
Manual Section: Cab Climate Control p. 1009Frequently Asked Questions
Which New Holland telehandlers does this service manual cover, and does it include engine overhaul?
It is service manual 51546942, in English, dated October 2018. It covers the TH6.32, TH6.36, TH7.32, TH7.37, TH7.42 and TH9.35 Stage IV telescopic handlers in Standard, S, PLUS and ELITE versions. Standard, S and PLUS machines run engine F4HFE413Z*B002 (89 kW). ELITE machines run F4HFE4149*B001 (96 kW). The engine chapter covers removal and the fuel, air, SCR and cooling systems. It does not cover engine inspection or overhaul. For those, it refers you to the specific engine service manual. p. 3
What are the TH6.32 to TH9.35 fluid capacities?
Engine oil is 12 l (3.2 US gal) with a filter change. The cooling system takes 21 L (5.5 US gal), the fuel tank 138 L (36.5 US gal) and the DEF/AdBlue tank 32 l (8.4 US gal). Total hydraulic system capacity is 157 L (41.5 US gal). Total transmission capacity is 21.45 L (5.67 US gal). The front and rear axle figure is 8 L (2.1 US gal), and each wheel reduction gear takes 0.8 L (0.2 US gal). The A/C charge is 1150 g of HFC R134A. p. 43
What hydraulic, steering and brake specifications does the manual give?
The variable displacement pump cuts off at 260 bar (3770 psi). The steering relief valve is set at 170 - 178 bar (2465 - 2581 psi). The shock valve is set at 240 bar (3480 psi) ± 5 bar (72 psi), on a 250 cm³/rev steering unit. Maximum hydraulic brake oil pressure is 80 bar (1160 psi). Transmission system pressure is 16 bar ± 2 bar on the Carraro TCH90 SD. Wheel nuts are torqued to 800 N·m (590 lb ft). Peak engine torque is 549 N·m (404.9 lb ft), or 591 N·m (435.9 lb ft) on the ELITE, at 1500 RPM. p. 944
Does the manual list fault codes for the telehandler controllers?
Yes. The Fault codes chapter gives each code its own entry, with context, cause, possible failure modes and a solution. It covers the engine control unit (ECU), the transmission control unit (TCU) and the UCM. Examples include 4449 - (DTC 1161) Battery voltage is higher than expected [ECU] and 6730 - (DTC 1A4A) DEF/AdBlue over pressure failure [ECU]. Others are 127-1 Side Drive Transmission Kprop pressure fail [TCU] and 9939 - (DTC 26D3) Oil Pressure Too Low. p. 1991
What is inside this manual: schematics, fault codes, overhaul procedures?
It has separate electrical schematic sets for Standard, S and PLUS models and for ELITE models. Examples are sheet 02 for the starting circuit, sheet 10 for the ECU core engine and sheet 19 for the TCU transmission solenoid valves. It also has engine schematics with fuel injection, a circuit color index and harness and connector pinouts. There are hydraulic schemas for non-Elite and Elite machines, plus the pilot system, brakes and steering. Removal, disassembly and assembly procedures cover the transmission, axles, brakes, pumps, valves, cylinders and telescopic arm. SAR calibration is included too. p. 1155
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