New Holland FR450 TIER 3 User manual

Part number 47812470
English
February 2015
Replaces part number 47688004
SERVICE MANUAL
FR450 / FR500 / FR600 / FR700 / FR850
Forage Harvester
Printedin U.S.A.
© 2015 CNH Industrial Belgium N.V. All Rights Reserved.
NewHolland is a trademark registered in the United States and many other countries,
owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

SERVICEMANUAL
FR
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LinkProduct/Engine
ProductMarketProductEngine
FR850FR850TIER2[5803-]NorthAmericaFVAE2884X*B200
FR450FR450TIER3[5803-]NorthAmericaF2CE9684U*E151
FR500FR500TIER4ANorthAmericaF3BFE613E*A
FR600FR600TIER3[5803-]NorthAmericaF3CE0684E*E920
FR450FR450TIER4ANorthAmericaF2CFE613A*A
FR500FR500TIER3[5803-]NorthAmericaF3BE0684J*E919
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Contents
INTRODUCTION
Engine.......................................................................................10
[10.001]Engineandcrankcase.............................................................10.1
[10.218]Fuelinjectionsystem...............................................................10.2
[10.400]Enginecoolingsystem.............................................................10.3
[10.414]Fananddrive......................................................................10.4
[10.418]Rotaryscreen......................................................................10.5
Maingearboxanddrive...............................................................14
[14.100]Maingearboxanddrive............................................................14.1
Transmission..............................................................................21
[21.114]Mechanicaltransmission...........................................................21.1
[21.120]Gearbox............................................................................21.2
[21.130]Mechanicaltransmissionexternalcontrols.........................................21.3
[21.100]Mechanicaltransmissionlubricationsystem.......................................21.4
[21.145]Gearboxinternalcomponents......................................................21.5
[21.182]Differential..........................................................................21.6
Four-WheelDrive(4WD)system..................................................23
[23.101]Mechanicalcontrol.................................................................23.1
[23.304]Four-WheelDrive(4WD)gearbox.................................................23.2
Frontaxlesystem.......................................................................25
[25.100]Poweredfrontaxle.................................................................25.1
[25.102]Frontbevelgearsetanddifferential...............................................25.2
[25.310]Finaldrives.........................................................................25.3
Rearaxlesystem........................................................................27
[27.450]Rear-poweredsteerableaxle......................................................27.1
[27.550]Non-poweredrearaxle.............................................................27.2
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Hydrostaticdrive.........................................................................29
[29.100]Transmissionandsteeringhydrostaticcontrol.....................................29.1
[29.218]Pumpandmotorcomponents......................................................29.2
[29.202]Hydrostatictransmission...........................................................29.3
Brakesandcontrols....................................................................33
[33.202]Hydraulicservicebrakes...........................................................33.1
[33.110]Parkingbrakeorparkinglock......................................................33.2
Hydraulicsystems.......................................................................35
[35.000]Hydraulicsystems..................................................................35.1
[35.106]Variabledisplacementpump.......................................................35.2
[35.204]Remotecontrolvalves.............................................................35.3
[35.300]Reservoir,cooler,andlters........................................................35.4
[35.359]Maincontrolvalve..................................................................35.5
[35.350]Safetyandmainreliefvalves......................................................35.6
[35.600]Highowhydraulics................................................................35.7
[35.410]Headerorattachmentheightsystem..............................................35.8
[35.602]Headerorattachmentlevelingsystem.............................................35.9
[35.514]Upperfeedrollgearboxsystem..................................................35.10
[35.516]Cutterheaddrivesystem.........................................................35.11
[35.530]Spoutrotationcircuit.............................................................35.12
[35.532]Spoutraisingsystem.............................................................35.13
[35.534]Spoutdeectorsystem...........................................................35.14
Steering.....................................................................................41
[41.101]Steeringcontrol....................................................................41.1
[41.200]Hydrauliccontrolcomponents......................................................41.2
[41.206]Pump...............................................................................41.3
[41.216]Cylinders...........................................................................41.4
[41.432]Autoguidancesteering.............................................................41.5
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Wheels......................................................................................44
[44.511]Frontwheels........................................................................44.1
[44.520]Rearwheels........................................................................44.2
Cabclimatecontrol.....................................................................50
[50.100]Heating.............................................................................50.1
[50.200]Airconditioning.....................................................................50.2
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.100]Harnessesandconnectors.........................................................55.2
[55.015]Enginecontrolsystem..............................................................55.3
[55.010]Fuelinjectionsystem...............................................................55.4
[55.014]Engineintakeandexhaustsystem.................................................55.5
[55.988]SelectiveCatalyticReduction(SCR)electricalsystem............................55.6
[55.012]Enginecoolingsystem.............................................................55.7
[55.013]Engineoilsystem..................................................................55.8
[55.512]Cabcontrols........................................................................55.9
[55.640]Electronicmodules...............................................................55.10
[55.610]Groundspeedcontrol............................................................55.11
[55.019]Hydrostaticdrivecontrolsystem.................................................55.12
[55.051]CabHeating,Ventilation,andAir-Conditioning(HVAC)controls.................55.13
[55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem...............55.14
[55.421]Feedingcontrolsystem..........................................................55.15
[55.800]Metaldetector....................................................................55.16
[55.820]Choppingandcuttingcontrolsystems...........................................55.17
[55.830]Rotaryscreendriveandcleaning................................................55.18
[55.680]Autopilot/Autoguidance..........................................................55.19
[55.450]Ejectingcontrolsystem..........................................................55.20
[55.408]Warningindicators,alarms,andinstruments....................................55.21
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[55.DTC]FAULTCODES..................................................................55.22
Attachments/Headers..................................................................58
[58.900]Beltfeeding........................................................................58.1
Productfeeding..........................................................................60
[60.103]Lowerfeedrolls....................................................................60.1
[60.107]Upperfeedrolls....................................................................60.2
[60.155]Metaldetector......................................................................60.3
Chopping...................................................................................64
[64.100]Cutterhead.........................................................................64.1
[64.106]Drum...............................................................................64.2
[64.130]Drumgearbox......................................................................64.3
[64.140]Sharpeningsystem.................................................................64.4
[64.150]Shearbar...........................................................................64.5
[64.160]Cropprocessor.....................................................................64.6
[64.170]Transitionchannel/concaveandlever.............................................64.7
Ejection.....................................................................................70
[70.120]Blower..............................................................................70.1
[70.140]Spout...............................................................................70.2
Platform,cab,bodywork,anddecals.............................................90
[90.105]Machineshieldsandguards.......................................................90.1
[90.150]Cab.................................................................................90.2
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INTRODUCTION
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Contents
INTRODUCTION
Basicinstructions-HowtouseandnavigatethroughthisManual.............................3
Advice.........................................................................................10
NotetotheOwner(*).........................................................................11
Safetyrules...................................................................................12
Safetyrules-Ecologyandtheenvironment..................................................13
Safetyrules...................................................................................14
Personalsafety...............................................................................17
Basicinstructions-Shopandassembly......................................................18
Torque........................................................................................20
Basicinstructions-ChainWearT ables-RollerChains......................................22
Conversionfactors............................................................................24
GeneralspecicationSystemprotectiondata................................................25
Productidentication..........................................................................28
(*)Seecontentforspecicmodels
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INTRODUCTION
Basicinstructions-HowtouseandnavigatethroughthisManual
Technicalinformation
Thismanualhasbeenproducedbyanewtechnicalinformationsystem.Thisnewsystemisdesignedtodeliver
technicalinformationelectronicallythroughWebdelivery(eTim),DVDandinpapermanuals.Acodingsystemcalled
SAPhasbeendevelopedtolinkthetechnicalinformationtootherProductSupportfunctions,e.g.,Warranty.
Technicalinformationiswrittentosupportthemaintenanceandserviceofthefunctionsorsystemsonacustomer's
machine.Whenacustomerhasaconcernonhismachineitisusuallybecauseafunctionorsystemonhismachine
isnotworkingatall,isnotworkingefciently,orisnotrespondingcorrectlytohiscommands.Whenyoureferto
thetechnicalinformationinthismanualtoresolvethatcustomer'sconcern,youwillndalltheinformationclassied
usingtheSAPcoding,accordingtothefunctionsorsystemsonthatmachine.Onceyouhavelocatedthetechnical
informationforthatfunctionorsystemthenyouwillndallthemechanical,electricalorhydraulicdevices,compo-
nents,assembliesandsubassembliesforthatfunctionorsystem.Youwillalsondallthetypesofinformationthat
havebeenwrittenforthatfunctionorsystem,thetechnicaldata(specications),thefunctionaldata(howitworks),
thediagnosticdata(faultcodesandtroubleshooting)andtheservicedata(remove,installadjust,etc.).
ByintegratingSAPcodingintotechnicalinformation,youwillbeabletosearchandretrievejusttherightpieceof
technicalinformationyouneedtoresolvethatcustomer'sconcernonhismachine.Thisismadepossiblebyattaching
3categoriestoeachpieceoftechnicalinformationduringtheauthoringprocess.
TherstcategoryistheLocation,thesecondcategoryistheInformationTypeandthethirdcategoryistheProduct:
•LOCATION-isthecomponentorfunctiononthemachine,thatthepieceoftechnicalinformationisgoingtodescribe
e.g.Fueltank.
•INFORMATIONTYPE-isthepieceoftechnicalinformationthathasbeenwrittenforaparticularcomponentor
functiononthemachinee.g.CapacitywouldbeatypeofTechnicalDatathatwoulddescribetheamountoffuel
heldbytheFueltank.
•PRODUCT-isthemodelforwhichthepieceoftechnicalinformationiswritten.
Everypieceoftechnicalinformationwillhavethose3categoriesattachedtoit.Youwillbeabletouseanycombination
ofthosecategoriestondtherightpieceoftechnicalinformationyouneedtoresolvethatcustomer'sconcernonhis
machine.
Thatinformationcouldbe:
•thedescriptionofhowtoremovethecylinderhead
•atableofspecicationsforahydraulicpump
•afaultcode
•atroubleshootingtable
•aspecialtool
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INTRODUCTION
Howtousethismanual
ThismanualisdividedintoSections.EachSectionisthendividedintoChapters.Contentspagesareincludedatthe
beginningofthemanual,theninsideeverySectionandinsideeveryChapter.AnalphabeticalIndexisincludedatthe
endofaChapter.PagenumberreferencesareincludedforeverypieceoftechnicalinformationlistedintheChapter
ContentsorChapterIndex.
EachChapterisdividedintofourInformationtypes:
•TechnicalData(specications)forallthemechanical,electricalorhydraulicdevices,componentsand,assemblies.
•FunctionalData(howitworks)forallthemechanical,electricalorhydraulicdevices,componentsandassemblies.
•DiagnosticData(faultcodes,electricalandhydraulictroubleshooting)forallthemechanical,electricalorhydraulic
devices,componentsandassemblies.
•ServiceData(removedisassembly,assemble,install)forallthemechanical,electricalorhydraulicdevices,com-
ponentsandassemblies.
Sections
Sectionsaregroupedaccordingtothemainfunctionsorasystemsonthemachine.EachSectionisidentiedbya
number00,35,55,etc.TheamountofSectionsincludedinthemanualwilldependonthetypeandfunctionofthe
machinethatthemanualiswrittenfor.EachSectionhasaContentspagelistedinalphabetic/numericorder.This
tableillustrateswhichSectionscouldbeincludedinamanualforaparticularproduct.
PRODUCT
Tractors
Vehicleswithworkingarms:backhoes,
excavators,skidsteers,….
Combines,forageharvesters,balers,….
Seeding,planting,oating,spraying
equipment,….
SECTIONMountedequipmentandtools,….
00-Maintenance
05-Machinecompletionandequipment
10-Engine
14-Maingearboxanddrive
18-Clutch
21-Transmission
23-Fourwheeldrivesystem
25-Frontaxlesystem
27-Rearaxlesystem
29-Hydrostaticdrive
31-Implementpowertake-off
33-Brakesandcontrols
35-Hydraulicsystems
36-Pneumaticsystem
37-Hitches,drawbarsandimplementcouplings
39-Framesandballasting
41-Steering
44-Wheels
46-Steeringclutches
48-Tracksandtracksuspension
50-Cabclimatecontrol
55-Electricalsystems
56-Grapeharvestershaking
58-Attachments/headers
60-Productfeeding
61-Meteringsystem
62-Pressing-Baleformation
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INTRODUCTION
63-Chemicalapplicators
64-Chopping
66-Threshing
68-Tying/Wrapping/Twisting
69-Balewagons
70-Ejection
71-Lubricationsystem
72-Separation
73-Residuehandling
74-Cleaning
75-Soilpreparation/Finishing
76-Secondarycleaning/Destemmer
77-Seeding
78-Spraying
79-Planting
80-Cropstorage/Unloading
82-Frontloaderandbucket
83-T elescopicsinglearm
84-Booms,dippersandbuckets
86-Dozerbladeandarm
88-Accessories
89-Tools
90-Platform,cab,bodyworkanddecals
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INTRODUCTION
Sectioncontents
SectionNumberDescription
Maintenance00
Machinecompletionandequipment05
Engine10
Maingearboxanddrive14
Clutch18
Transmission21
Fourwheeldrivesystem23
Frontaxlesystem25
Rearaxlesystem27
Hydrostaticdrive29
Implementpowertake-off31
Brakesandcontrols33
Hydraulicsystems35
ThisSectioncoversthecentralpartsofthehydraulic
system.Thecomponentsthatarededicatedtoa
specicfunctionarelistedintheChapterwhereallthe
technicalinformationforthatfunctionisincluded.
Pneumaticsystem36
ThisSectioncoversthepneumaticsystem.The
componentsthatarededicatedtoaspecicfunctionare
listedintheChapterwhereallthetechnicalinformation
forthatfunctionisincluded.
Hitches,drawbarsandimplementcouplings37
Framesandballasting39
Steering41
Wheels44
Steeringclutches46
Tracksandtracksuspension48
Cabclimatecontrol50
Electricalsystems55
TheSectioncoversthecentralpartsoftheelectrical,
electronic,andlightingsystems.Thecomponentsthat
arededicatedtoaspecicfunctionarelistedinthe
Chapterwhereallthetechnicalinformationforthat
functionisincluded.
Grapeharvestershaking56
Attachments/headers58
Productfeeding60
Meteringsystem61
Pressing-Baleformation62
Chemicalapplicators63
Chopping64
Threshing66
Tying/Wrapping/Twisting68
Balewagons69
Ejection70
Lubricationsystem71
Separation72
Residuehandling73
Cleaning74
Soilpreparation/Finishing75
Secondarycleaning/Destemmer76
Seeding77
Spraying78
Planting79
Cropstorage/Unloading80
Frontloaderandbucket82
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INTRODUCTION
SectionNumberDescription
Telescopicsinglearm83
Booms,dippersandbuckets84
Dozerbladeandarm86
Accessories88
Tools89
Platform,cab,bodyworkanddecals90
ThisSectioncoversallthemainfunctionsandsystems
relatedtothebodyofthemachine,includingthe
operatorscabandtheplatform.
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INTRODUCTION
Chapters
EachChapterisidentiedbyanumbere.g.HydraulicSystems-Maincheckvalve-35.359.Therstnumberis
identicaltotheSectionnumberi.e.Chapter35.359isinsideSection35,HydraulicSystems.Thesecondnumberis
representativeoftheChaptercontainedwithintheSection.
CONTENTS
TheChapterContentslistsallthetechnicaldata(specications),functionaldata(howitworks),servicedata(remove,
installadjust,etc..)anddiagnosticdata(faultcodesandtroubleshooting)thathavebeenwritteninthatChapterfor
thatfunctionorsystemonthemachine.
Contents
HYDRAULICSYSTEMS-35
Maincontrolvalve-359
FUNCTIONALDATA
Maincontrolvalve-Sectionalview(35.359-C.10.A.30)
TECHNICALDATA
Maincontrolvalve-Generalspecications(35.359-D.40.A.10)
SERVICE
Maincontrolvalve-Remove(35.359-F .10.A.10)
INDEX
TheChapterIndexlistsinalphabeticalorderallthetypesofinformation(calledInformationUnits)thathavebeen
writteninthatChapterforthatfunctionorsystemonthemachine.
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INTRODUCTION
Informationunitsandinformationsearch
Eachchapteriscomposedofinformationunits.EachinformationunithasapagereferencewithinthatChapter.The
informationunitsprovideaquickandeasywaytondjusttherightpieceoftechnicalinformationyouarelookingfor.
ExampleinformationunitMaincontrolvalve-SectionalView(35.359)
InformationUnitSAPcode35Hydraulicsystems
SAPcodeclassication359Maincontrolvalve
Pageheaderandfooter
Thepageheaderwillcontainthefollowingreferences:
•SectionandChapterdescription
Thepagefooterwillcontainthefollowingreferences:
•PublicationnumberforthatManual,SectionorChapter.
•Versionreferenceforthatpublication.
•Publicationdate
•Section,chapterandpagereferencee.g.35.359/9
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INTRODUCTION
Advice
Allrepairandmaintenanceworkslistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven;andusing,wheneverappropriate,thespecialtools.
Anyonewhocarriesouttheaboveoperationswithoutcomplyingwiththeinstructionsshallberesponsibleforthe
subsequentdamages.
Themanufacturerandalltheorganizationsofit'sdistributionchain,including-withoutlimitation-national,regional,
orlocaldealers,rejectanyresponsibilityfordamagesduetotheanomalousbehaviorofpartsand/orcomponentsnot
approvedbythemanufacturerhimself,includingthoseusedfortheservicingorrepairoftheproductmanufactured
ormarketedbythemanufacturer.Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedor
marketedbythemanufacturerincaseofdamagesduetoananomalousbehaviorofpartsand/orcomponentsnot
approvedbythemanufacturer.
Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor
continuousimprovement.Someinformationmaynotbeupdatedduetomodicationsofatechnicalorcommercial
type,aswellastosuitthelawsandregulationsofdifferentcountries.
Incaseofquestions,refertoyourSalesandServiceNetworks.
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INTRODUCTION
NotetotheOwner
FR450NA
FR500NA
FR600NA
FR850NA
Enginerepairinformation:
Theenginerepairinformationisnotcontainedwithinthismanual.
Forenginerepairinformation,pleaserefertotherespectiveServiceManualfortheenginetypeusedinyourvehicle.
FaultCodeResolution(FCR)information:
ForFCRinformation,pleaserefertotheElectronicServiceT ool(EST)ortotheinformationgiveninthepaperor
electronicversionofthismanual.
ElectronicServiceTool(EST)information:
TheESTinformationandhowtohandleControlModules(CM)(e.g.:resettingoftheCM,etc.)isnotcontainedwithin
thismanual.
ForESTinformation,pleaserefertotheElectronicServiceToolUser'sGuide.
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INTRODUCTION
Safetyrules
Personalsafety
Thisisthesafetyalertsymbol.Itisusedtoalertyoutopotentialpersonalinjuryhazards.Obeyall
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury.
ThroughoutthismanualyouwillndthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialin-
structions.Theseprecautionsareintendedforthepersonalsafetyofyouandthoseworkingwithyou.
Readandunderstandallthesafetymessagesinthismanualbeforeyouoperateorservicethemachine.
DANGERindicatesahazardoussituationthat,ifnotavoided,willresultindeathorseriousinjury.
WARNINGindicatesahazardoussituationthat,ifnotavoided,couldresultindeathorseriousinjury.
CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury.
FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT
INDEATHORSERIOUSINJURY .
Machinesafety
NOTICE:Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage.
ThroughoutthismanualyouwillndthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor
propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
Information
NOTE:Noteindicatesadditionalinformationthatclariessteps,procedures,orotherinformationinthismanual.
ThroughoutthismanualyouwillndthewordNotefollowedbyadditionalinformationaboutastep,procedure,or
otherinformationinthemanual.ThewordNoteisnotintendedtoaddresspersonalsafetyorpropertydamage.
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INTRODUCTION
Safetyrules-Ecologyandtheenvironment
Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe
treatmentofsomeofthesubstancesthatadvancedtechnologyrequires,soundjudgmentshouldgoverntheuseand
disposalofproductsofachemicalandpetrochemicalnature.
Familiarizeyourselfwiththerelativelegislationapplicabletoyourcountry,andmakesurethatyouunderstandthis
legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,anti-freeze,
cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use,
anddisposeofthesesubstances.
Helpfulhints
•Avoidtheuseofcansorotherinappropriatepressurizedfueldeliverysystemstolltanks.Suchdeliverysystems
maycauseconsiderablespillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostoftheseproductscontainsubstances
thatmaybeharmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhenyoudrainuidssuchasusedenginecoolantmixtures,engineoil,hydraulicuid,brakeuid,
etc.Donotmixdrainedbrakeuidsorfuelswithlubricants.Storealldraineduidssafelyuntilyoucandisposeof
theuidsinaproperwaythatcomplieswithalllocallegislationandavailableresources.
•Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly.
•Theair-conditioningsystemcontainsgasesthatshouldnotbereleasedintotheatmosphere.Consultanair-condi-
tioningspecialistoruseaspecialextractortorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingsystemorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringwelding.Penetratingweldsplattermayburnaholeorweakenhoses,allowingthelossofoils,
coolant,etc.
Batteryrecycling
Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful
effectontheenvironmentifthebatteriesarenotproperlyrecycledafteruse.Improper
disposalofbatteriescancontaminatethesoil,groundwater,andwaterways.NEW
HOLLANDstronglyrecommendsthatyoureturnallusedbatteriestoaNEWHOLLAND
dealer,whowilldisposeoftheusedbatteriesorrecycletheusedbatteriesproperly.In
somecountries,thisisalegalrequirement.
Mandatorybatteryrecycling
NOTE:ThefollowingrequirementsaremandatoryinBrazil.
Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead,
CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany
batteries.Donotdisposeofbatteriesinyourhouseholdgarbage.
Pointsofsaleareobligedto:
•Acceptthereturnofyourusedbatteries
•Storethereturnedbatteriesinasuitablelocation
•Sendthereturnedbatteriestothebatterymanufacturerforrecycling
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