New Holland TL80A TL90A TL100A Service Manual [Tractor]

Complete Updated (08/2006) Factory Service Repair Manual (87580875) New Holland TL80A TL90A TL100A Tractors in PDF format. Step by step Instructions, illustrations, diagrams for repair, service, maintain your machine. Digital PDF format, searchable and bookmarked, clean, sharp images.
PDF Manual:

1582 pages
Instant download – You will receive link for download on your email immediately after payment.
Lifetime Download (by request)
Compatible with PC, MAC/ Tablet / Smartphone
Searchable PDF
Built-in index for instant information search
Bookmarks
Printable: pages or entire manual
Zoomable: detailed exploded diagrams, picture
Models

New Holland
TL80A
TL90A
TL100A

Contents

General
Engine
Clutch
Transmissions
FWD transfer box
Front axle mechanical transmission
Rear axle mechanical transmission
Power take-off
Brakes
Hydraulic systems
Steering
Axles and wheels
Auxiliary units
Electrical systems
Wiring Diagrams
Cab, platform, and bodywork
Full contents

GENERAL

General

General Instructions
Health and Safety
Precautionary Statements
Safety
Ecology and the Environment
Minimum Hardware Tightening Torques
Federal Emissions Warranty
Consumables

ENGINE

Engine

Specifications
Tightening Torques
Special Tools
Description and Operation
Sectional Views
Troubleshooting
Overhaul
Engine
Removal
Installation
Compression Test
Considerations
Uniform Compression
Low Compression Readings
Disassembly
Crankshaft Front Seal Removal
Crankshaft Rear Seal Removal
Assembly
Bushings
Tappet
Camshaft
Oil Nozzle
Crankshaft
Connecting Rod and Piston
Installing the Piston Connecting Rod Assemblies in the Cylinder
Big End Cap Assembly
Thermostat Valve
Cylinder Head
Fuel Injectors
Rocker Arm Assembly
Timing Gear
Injection Pump
Counterweight and Balancer
Hydraulic Pump Drive Gear
Timing Gear Casing
Crankshaft Rear Seal
Flywheel
Oil Pump
Oil Sump
Crankshaft Front Seal
Crankshaft Front Pulley
Cooling System Union
Coolant Pump
Fan–Alternator Pulley
Auxiliary Drive Belt
Exhaust Manifold — Turbocharger
Injector Feed Pipe
Priming Pump — Feed Pipe
Installing The Pipes Between The Fuel Supply and Injection Pumps,
Pre-Heating System and Tappet Cover
Starter Motor
Checks, Measurements and Repairs
Cylinder Block
Crankshaft
Main Crankshaft Tolerances
Connecting Rods
Pistons
Measuring the Piston Diameter
Piston Pins
Conditions for Correct Pin-piston Coupling
Piston Rings
Camshaft and Valves
Decarbonizing and grinding valves
Checking Valve Spring Flexibility
Tappets
Camshaft
Cylinder Head
Crankshaft Front Seal
Crankshaft Rear Seal
Valve Tappet and Rocker Arm

Cooling System

Specifications
Description of Operation
Radiator
Coolant Thermometer
Thermostat Valve
Sectional Views
Overhaul
Coolant Pump
Removal
Installation
Thermostat Valve
Removal
Installation
Radiator
Removal
Installation
Coolant Pump and Alternator Belts
Tension Adjustment
Download Link:
New Holland TL80A TL90A TL100A Service Manual [Tractor]

Lubrication System

Specifications
Lubrication System Components
Oil Pressure Indicator
Oil Filter
Oil Pump

Fuel System

Specifications
Special Tools
Description and Operation
Turbocharged Engine
Manifold Pressure Compensator (LDA)
Description
Operation
All Models
Electrical Cold-start Accelerator (KKSB)
Overhaul
Fuel Injectors
Removal
Installation
BOSCH Fuel Injection Pump
Removal
Locking the Injection Pump
Timing the Fuel Injection Pump on a Workbench
Installation
Timing the Pump on the Tractor

Clutch

Specifications
Tightening Torques
Special Tools
Description and Operation
Cross Sectional Views
Troubleshooting
Overhaul
Inspection and Adjustment
Dual Clutch
Clutch Pedal
Dual Clutch
Removal
Installation
Disassembly
Assembly
Adjust Release Levers
Single Disk Clutch
Inspection

TRANSMISSIONS

Synchro Command Mechanical Shuttle Transmission

Reverser (Mechanical Shuttle Transmissions)
Specifications
Tightening Torques
Special Tools
Description and Operation
Cross-Sectional Views
Troubleshooting
Overhaul
Clutch-Reverser Casing
Removal
Disassembly
Assembly
Installation

Reverser and Creeper Unit for Mechanical Shuttle Transmission

Specifications
Tightening Torques
Special Tools
Description and Operation
Cross-Sectional Views
Troubleshooting
Overhaul
Reverser-Clutch Casing and Creeper Unit
Removal
Disassembly
Assembly
Installation

Dual Command Power Shuttle

Specifications
Tightening Torques
Special Tools
Description and Operation
Cross-Sectional Views
Overhaul
Clutch Casing with Power Shuttle and Dual Command
Removal
Disassembly
Assembly
Installation
Clutch (A)
Disassembly
Assembly
Installing on Clutch Casing
Clutch (B)
Disassembly — Assembly

FWD TRANSFER BOX

FWD Transfer Box

Specifications
Tightening Torques
Special Tools
Description and Operation
Cross-Sectional Views
Electro-Hydraulic Four Wheel Drive (FWD)
Troubleshooting
Overhaul
Services Control Valve
Removal
Installation
Disassembly
Assembly
Drive Gear
Removal
Installation
Drive Gear Housing
Removal
Installation

FRONT AXLE MECHANICAL TRANSMISSION

Front Axle Mechanical Transmission

Specifications
Tightening Torques
Special Tools
Description and Operation
Cross-Sectional Views
Limited-Slip Self-Locking Differential
Front Differential Lock
Troubleshooting
Overhaul
Front Axle
Removal
Installation
Correctly Installing Axle Support to the Engine
Disassembly
Assembly
Front Axle Differential
Backlash Between Side and Planetary Pinion Teeth
Front Axle Differential with Limited-Slip Unit
Removal
Disassembly
Assembly
Installation
Front Differential Lock Clutch Assembly
Disassembly
Assembly
Front Epicyclic Final Drive
Removal
Installation
Wheel Hub Seal Replacement
Steering Knuckle Pins and Bearings Replacement
Adjustments
Stub Axle
Pinion

REAR AXLE MECHANICAL TRANSMISSION

Rear Axle Mechanical Transmission

Specifications
Drive and Differential Data
Final Drive Data
Tightening Torques
Special Tools
Description and Operation
Sectional Views
Hydraulically Controlled Rear Differential Lock
Troubleshooting
Drive and Differential
Final Drive
Differential Lock
Overhaul
Rear Gearbox — Transmission Casing
Removal
Installation
Disassembly
Assembly, Adjustment, Installation
Final Drive Casing
Removal
Installation
Epicyclic Final Drive
Disassembly
Assembly
Drive Wheel Shaft
Disassembly
Assembly
Differential

POWER TAKE-OFF

Mechanical Power Take-Off

Specifications
Special Tools
Tightening Torques
Description and Operation
Sectional Views
Mechanically Operated PTO
Troubleshooting
Overhaul
Power Take-Off Housing
Removal
Installation
Power Take-Off Shafts
Disassembly
Assembly

Electro-Hydraulic Power Take-Off

Specification
Special Tools
Tightening Torques
Description and Operation
Sectional Views
Electro-Hydraulic PTO
PTO Engagement
Troubleshooting
Overhaul
PTO Clutch Brake
Removal
Installation
PTO Housing
Removal
Installation
Disassembly
Assembly

BRAKES

Brakes

Specifications
Tightening Torques
Description of Operation
Sectional Views
Troubleshooting
Overhaul
Handbrake Lever
Adjustment
Parking Brake Housing
Removal
Disassembly
Assembly
Installation
Brake System Bleeding
Brake Pump
Removal
Installation
Adjustment of Pedal Travel
Brake Units
Removal
Installation

HYDRAULIC SYSTEMS

Hydraulic System Description

Specifications
Precautionary Statements
Description and Operation
Power Steering and Lift Pump Components
Hydraulic System Configurations
Hydraulic System — General Description
Hydraulic Power Lift (HPL) Control
Rear Auxiliary (Remote) Control Valves
Rear Remote Valve Arrangement
Mid-Mount Control Remote Control Valves
Auxiliary Control Valve Oil Flow

Mechanically Operated Hydraulic Power Lift (HPL)

Specifications
Torque Valves
Sectional Views
Special Tools
Troubleshooting
Description and Operation
Hydraulic Power Lift (HPL) Control Valve Oil Flow
Lower Phase
Neutral Phase
Lift Phase
Overhaul
HPL Cover
Removal
Disassembly
Assembly
Adjusting the HPL on a Workbench
Adjusting the HPL on the Tractor
Fast Raise/Lower Control Upper Stroke Limit
HPL Control Valve
Removal
Disassembly
Assembly
Installation
HPL Pump Seals
Lift Pressure Relief Valve

KONTAK Auxiliary Control Valves

Sectional Views
Description and Operation
Kontak Remote Valve Oil Flow
Double-Acting Raise Position
Double-Acting Lower Position
Single-Acting Raise Position
Single-Acting Lower Position
Kontak Remote Valve With Detent Release and Float Oil Flow
Double-Acting Raise Position
Double-Acting Lower Position
Double-Acting Float Position

BOSCH Auxiliary Control Valves

Sectional Views
Description and Operation
Bosch Closed-Center Remote Control Valves With Open-Center Pump
Bosch Remote Valve With Detent (Non-Adjustable), Float, and Flow Control Oil Flow
Neutral Position
Raise Position
Lower Position
Float Position
BOSCH Remote Valves
Removal
Disassembly
Assembly
Installation

Kontak Mid-Mount Auxiliary Control Valves

Sectional Views
Torque Values
Description and Operation
Kontak Mid-Mount Remote Valve Oil Flow
Flow Control Valve
Disassembly
Assembly
Mid-Mount Remote Valves
Disassembly
Assembly

Low Pressure Hydraulic System

Low-Pressure, Steering and Lubrication Circuit
Description and Operation
Low Pressure Circuit Hydraulic Pump
Power Shuttle Transmissions with Dual Command
Services Control Valve (Models with Power Shuttle Transmission)
Services Control Valve (Models with Mechanical Shuttle Transmission)
Lubrication Oil Flow on TLA Models with Power Shuttle Transmission
and Dual Command
Oil Flow
Synchro Command Mechanical Shuttle Transmission on TLA, TLA and TLA Standard Models
Dual Command Power Shuttle Transmission on TLA, TLA and TLA Deluxe Models
Rear Differential Lock (Hydraulic Control) on all TLA, TLA and TLA
Deluxe Models and on Standard Models with FWD
Front Differential Lock (Hydraulic Control) on TLA, TLA and TLA
Deluxe Models with FWD
Electro-Hydraulically Disengaged Four-Wheel Drive (FWD) — All Models
Power Take-Off [Electro-Hydraulic Engagement] (TLA Deluxe models)

Low-Pressure Hydraulic System Overhaul

Specifications
Sectional Views
Troubleshooting
Overhaul
Services Control Valve
Removal
Disassembly
Assembly
Installation

Hydraulic System Testing

Precautionary Statements
Special Tools
Test Procedures
Dual Command Clutch Pack Operating Pressure (Power Shuttle Transmission)
Low-pressure System Relief Valve Setting (Power Shuttle Transmission)
Low-pressure System Relief Valve Setting (Mechanical Shuttle Transmission)
Transmission Lubrication Relief Valve Setting (Power Shuttle Transmission)
Transmission Lubrication Relief Valve Setting (Mechanical Shuttle Transmission)
Steering System Relief Valve Setting (FWD or WD)
Steering System Pump Oil Flow
High-pressure System Relief Valve Setting
High-Pressure System Pump Oil Flow
PTO Clutch Pack Operating Pressure
PTO Clutch Brake Operating Pressure
PTO Clutch Lubrication Relief Valve Setting (Power Shuttle Transmission)
PTO Clutch Lubrication Relief Valve Setting (Mechanical Shuttle Transmission)
FWD Disengagement Pressure (Power Shuttle Transmission)
FWD Disengagement Pressure (Mechanical Shuttle Transmission)
Differential Lock Engagement Pressure (Power Shuttle Transmission)
Differential Lock Engagement Pressure (Mechanical Shuttle Transmission)

Walvoil Open-Center Mid-Mount Control Valves

Specifications
Tightening Torques
Sectional Views
Walvoil Mid-mount Valve Stack
Walvoil Mid-mount Components
Description of Operation
Joystick Control
Regenerative Lock-out Function
Control Valve Circuit
Hydraulic Diagram
nd Control Valve
Operation in the Neutral Phase (Figure )
st Control Valve
Operation in the Neutral Phase (Figure )
st and nd Control Valves
Operation in the Neutral Phase (Figure )
st Control Valve Operation
Lowering Phase
Float Phase
Lifting Phase
nd Control Valve Operation
Lifting Phase
Regenerative Phase
Lowering Phase
st and nd Control Valve Operation

STEERING

Hydrostatic Power Steering

Specifications
Tightening Torques
Troubleshooting
Special Tools
Component List
Description and Operation
Hydrostatic Power Steering (WD)
Hydrostatic Power Steering (FWD)
Operation
Steering Right
Steering Left
Manual Steering to Right
Manual Steering to Left
Overhaul
Power Steering Control Valve
Removal
Installation
Disassembly
Assembly
Power Steering Cylinder(s) (FWD)
Removal
Installation
Power Steering Cylinder (WD)
Removal
Installation
Power Steering Pump
Disassembly
Assembly
Testing the Steering System
Steering Control Valve
Checking Rotating Valve Wear
Checking Control Valve Return to Neutral
Checking the Seals for Leaks
Pressure Relief Valve

AXLES AND WHEELS

Axles and Wheels

Specifications
Description and Operation
Cross-Sectional Views
Tightening Torques
Special Tools
Troubleshooting
Overhaul
Front Axle Hub
Removal
Installation
Front Axle
Removal
Installation
Stub Axle
Removal
Installation
Adjustments
Checking Front Wheel Toe-In
Checking FWD Front Wheel Toe-In

AUXILIARY UNITS

Auxiliary Units

Safety Precautions
Specifications
Special Tools
Description and Operation
Main Components
Sanden SD H Model Compressor
Condenser
Filter/Dryer
Thermostatic Expansion Valve
Electronic Thermostatic Switch (Antifrost)
Evaporator
Warnings for Air Conditioning System Repair Operations
Cab Heating and Ventilation Controls
Ventilation
Electric Fan
Air Filter
Temperature Control Knob
Ignition Switch
Cab Air Conditioning Controls
Temperature Control Knob
Electric Fan Control Knob
Operation
Recovery, Recycling, Evacuation, Charging Station
Description
Leak Detector
Description and Operation
Maintenance
Air Conditioning System Maintenance
Compressor
Condenser
Filter/Dryer
Expansion Valve
Troubleshooting
Visual Inspection of Components
Problems and Possible Causes
Functional Tests
Checking Air Temperature
Checking for Gas Leaks (with Detector )
Compressor Drive Belt
Compressor Drive Belt Tension
Inspecting the Belt
Overhaul
Air Conditioner Compressor
Removal
Installation
Compressor Oil — Type and Quantity
Heating Pipes
Removal
Installation
Air Conditioner Pipes
Removal
Installation
Air Conditioner Condenser
Removal
Installation
Filter/Dryer
Removal
Installation
Cab Heating Unit
Removal
Installation
Air Conditioner Evaporator
Removal
Installation
Electric Fan
Removal
Installation

ELECTRICAL SYSTEMS

Instruments

Control panel
Indicator Lights
Analog/Digital Instruments
Instruments
Liquid Crystal Displays
Central Display
Advanced Keypad
Transmitters, Sensors and Switches
Maintenance

Components

General Information
Description and Operation
Dashboard Controls
Lights/horn Switch
Direction Indicators
Tail/Side Lights, Full Beam, Dipped Beam And Front Headlight Flash
Horn
Flashing Hazard Warning Lights Switch
Swivel Work Lights Switch
Differential Lock Switch
Four-wheel Drive Switch (version without cab)
Starter Switch
Advanced Keypad
Instrument Calibration Switch (version without advanced keypad)
Front Windscreen Washer/Wiper Control Lever (models without cab)
Right-hand Mudguard Controls (With Cab)
LIFT-O-MATIC Control Button
Gear Lever with Dual Command Push-buttons
Right-hand Mudguard Controls (Without Cab)
Controls on Right-hand Cab Upright
Lighting Control Switches
Rear Work Lights Control Switch
Windscreen Wiper/Washer Switch
Electrohydraulic PTO Control Switch (version with cab)
Rotating Beacon Light ON/OFF Switch
Front Work Lights Control Switch
Air Conditioning and Temperature Control
Air Conditioning Control Knob
Temperature Control Knob
Electric Fan Control Knob
Bulb Replacement
Front Work Lights Lamp
Front Sidelight and Direction Indicator Lamp
Work Lights Lamp Bulb
Front Side Light, Brake and Direction Indicator Lamp

Starting System

Specifications
Tightening Torques
Description and Operation
Fault Diagnosis
System Testing
Starting System Circuit Resistance (Voltage Drop)
Overhaul
Starter Motor
Removal
Installation
Disassembly
Assembly
Testing

Charging System

Specifications
Tightening Torques
Description and Operation
Charging System Testing
Precautions
Preliminary Checks
Battery Check
Driving Belt Check
Checking the Warning Lights on the Control Panel
Tests
Alternator Wire Connection
Charging Current and Regulated Voltage
Charging Circuit Voltage Drop
Maximum Alternator Output
Alternator Component Tests
Overhaul
Alternator
Removal
Disassembly
Assembly
Installation

Battery

Specifications
Description and operation
Overhaul
Battery
Removal
Installation
Battery Testing
Relative Density
Battery Maintenance
Dry-Charged Batteries
Charging the Battery
Tests
Battery Problems — Causes

Electrical Circuits

Description and Operation
Fuse and Relay Layout
Standard Deluxe with Mechanical Shuttle Transmission/Without Cab
Deluxe with Power Shuttle Transmission/Without Cab
Standard/Deluxe with Mechanical Shuttle Transmission/With Cab
Deluxe with Power Shuttle Transmission/With Cab
Power Sockets
Operator Safety Circuit
Grid Heater Relay
Grid Heater Control Module
Electronic Flasher Module
Ground Location Points
Symbols Used In Electrical Circuits
Wire Color Coding
Electrical Circuits

Components Testing

Components
Differential Lock Indicator Switch
Brake Fluid Level Switch
Low Transmission Oil Pressure Switch
Air Filter Clogged Switch
Lift Status Switch
Fuel Sediment Filter Switch
Engine Coolant Temperature Sensor
Brake Light Switch
Safety Pressure Switches / Italia Trailer Brake Valve Circuit Indicator
Handbrake Status Switch
Dual Command ( Speed Power Shift) Switches
Gear/Range Lever Position Sensors
Alternator
Engine Oil Pressure Sensor
Speed Sensors
Speed Sensor for Electronic Lift
Power Shuttle Control Unit Ground Speed Sensor
Switch and Clutch Pedal Potentiometer
Power Shuttle A/B Clutch Pressure Switches and Oil Temperature Sensor
Power Shuttle Lever
Radar
Fuel Level Indicator
WD Pressure Switch
PTO Speed Sensor
Seat Safety Switch
Electronic Lift Arm Position Potentiometer
Draft Pin Sensors (–)
Overhaul
Front Wiper Motor
Removal
Installation

Fault Codes

Introduction
Special Tools
Wiring Harness Repairs
Temporary Wiring Harness Repair
Harness Wire Replacement
Testing
Digital Multi-Meter
Electrical Tests
Continuity Test – Short to Ground
Voltage Measurement or Short to Positive Supply Volts
Resistance Test for Electrical Parts
Continuity Test – Check for Open Circuits
Circuit Components
Circuit Protection Devices
Fuses
Fuse Links
Circuit Control Devices
Switches
Flashers
Diodes
Resistance Devices
Potentiometers
Electromagnetic Devices
Relays
Solenoids
PWM Solenoid Valves
Sensors
Electronic Modules
Controller Area Network (CAN) System
Controller Locations
Fault Code Displays
H-Menu Diagnostic Mode
Error Code Listing
Transmission
Rear Power Take-Off (PTO)
Four Wheel Drive (FWD)
Differential Lock
Analogue Digital Instrument Cluster (ADIC)
Electronic Draft Control (EDC) not in North America
Calibration U-Codes
Transmission Error Code Listing
Rear Power Take-Off (PTO) Error Code Listing
Four Wheel Drive Error Code Listing
Differential Lock Error Code Listing
Analogue Digital Instrument Cluster (ADIC) Error Code Listing
Electronic Draft Control (EDC) Error Code Listing

HH Menu and Calibrations

Description and Operation
Instrument Panel Display
Calibrations
HH MENU Access
HH MENU of the Instrument Panel
HH MENU of the Dual Command Power Shuttle Transmission (PA)
HH MENU of the Advanced Keypad (JB)

CAN Bus Network

Description and Operation
Terminology
Troubleshooting
Testing
Repair

CAB, PLATFORM, AND BODYWORK

Removal of Components

Special Tools
Overhaul
Engine Hood
Removal
Installation
Platform
Removal
Installation
Operator’s Seat
Removal
Installation
Cab
Removal
Installation
Cab Doors
Removal
Installation
Cab Windows (Glued)
Removal
Installation
Cab Rear Window
Removal
Installation
Left-Hand Pillar Seal
Removal
Installation
Right-Hand Pillar Seal
Removal
Installation
Right-Hand Wall Padding
Removal
Installation
Left-Hand Wall Padding
Removal
Installation
Hydraulic Control Lever Guard
Removal
Installation
Cab Ceiling Trim
Removal
Installation