New Holland MegaCutter 512 User manual

Part number 47390184
1st edition English
April 2013
SERVICE MANUAL
Megacutter™512
Megacutter™530
Tractor Mounted Disc Mower-Conditioner
PrintedinU.S.A.
Copyright © 2013 CNH America LLC. All Rights Reserved. NewHollandisaregisteredtrademarkofCNH America LLC.
Racine Wisconsin 53404 U.S.A.

Contents
INTRODUCTION
Maingearboxanddrive...............................................................14
[14.100]Maingearboxanddrive............................................................14.1
PowerTake-Off(PTO).................................................................31
[31.201]PowerTake-Off(PTO)driveshaft..................................................31.1
[31.225]Clutches............................................................................31.2
Hydraulicsystems.......................................................................35
[35.415]Headerorattachmenttiltingsystem...............................................35.1
Electricalsystems.......................................................................55
[55.000]Electricalsystem...................................................................55.1
[55.511]Lightharnesses....................................................................55.2
Attachments/Headers..................................................................58
[58.110]Attachment/Headercuttingmechanism............................................58.1
Productfeeding..........................................................................60
[60.630]Flailconditioning...................................................................60.1
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INTRODUCTION
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Contents
INTRODUCTION
Foreword-Ecologyandtheenvironment......................................................3
Personalsafety.................................................................................4
Basicinstructions-Importantnoticeregardingequipmentservicing...........................5
Basicinstructions-Shopandassembly........................................................6
Torque-Minimumtighteningtorquesfornormalassembly.....................................8
Torque-Standardtorquedataforhydraulics.................................................11
Generalspecication-GeneralWelding.....................................................12
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INTRODUCTION
Foreword-Ecologyandtheenvironment
Soil,air,andwaterarevitalfactorsofagricultureandlifeingeneral.Whenlegislationdoesnotyetrulethetreatment
ofsomeofthesubstancesrequiredbyadvancedtechnology,soundjudgmentshouldgoverntheuseanddisposalof
productsofachemicalandpetrochemicalnature.
NOTE:Thefollowingarerecommendationsthatmaybeofassistance:
•Becomeacquaintedwithandensurethatyouunderstandtherelativelegislationapplicabletoyourcountry.
•Wherenolegislationexists,obtaininformationfromsuppliersofoils,lters,batteries,fuels,antifreeze,cleaning
agents,etc.,withregardtotheireffectonmanandnatureandhowtosafelystore,use,anddisposeofthese
substances.
•Agriculturalconsultantswill,inmanycases,beabletohelpyouaswell.
Helpfulhints
•Avoidllingtanksusingcansorinappropriatepressurizedfueldeliverysystemsthatmaycauseconsiderable
spillage.
•Ingeneral,avoidskincontactwithallfuels,oils,acids,solvents,etc.Mostofthemcontainsubstancesthatmaybe
harmfultoyourhealth.
•Modernoilscontainadditives.Donotburncontaminatedfuelsandorwasteoilsinordinaryheatingsystems.
•Avoidspillagewhendrainingoffusedenginecoolantmixtures,engine,gearboxandhydraulicoils,brakeuids,etc.
Donotmixdrainedbrakeuidsorfuelswithlubricants.Storethemsafelyuntiltheycanbedisposedofinaproper
waytocomplywithlocallegislationandavailableresources.
•Moderncoolantmixtures,i.e.antifreezeandotheradditives,shouldbereplacedeverytwoyears.Theyshouldnot
beallowedtogetintothesoil,butshouldbecollectedanddisposedofproperly.
•Donotopentheair-conditioningsystemyourself.Itcontainsgasesthatshouldnotbereleasedintotheatmosphere.
YourNEWHOLLANDAGRICULTUREdealerorairconditioningspecialisthasaspecialextractorforthispurpose
andwillhavetorechargethesystemproperly.
•Repairanyleaksordefectsintheenginecoolingorhydraulicsystemimmediately.
•Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure.
•Protecthosesduringweldingaspenetratingweldsplattermayburnaholeorweakenthem,allowingthelossof
oils,coolant,etc.
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INTRODUCTION
Personalsafety
WARNING
Riskofharmduringmaintenanceofthemachine!
Beforeyoustartservicingthemachine,attachaDONOTOPERATEwarningtagtothemachineina
visiblearea.
Failuretocomplycouldresultindeathorseriousinjury.W1242A
AttachaDONOTOPERATE(TAG)tothemachineinanareathatisclearlyvisiblewheneverthemachineisnot
operatingproperlyand/orrequiresservice.
Completethetaginformationforthe"REASON"thetagisattachedbydescribingthemalfunctionorservicerequired.
Validatethereasonforattachingthetagbysigningyournameinthedesignatedareaonthetag.
Thetagshouldonlyberemovedbythepersonwhosignedandattachedthetag,aftervalidatingtherepairsorservices
havebeencompleted.
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INTRODUCTION
Basicinstructions-Importantnoticeregardingequipmentservicing
Allrepairandmaintenanceworklistedinthismanualmustbecarriedoutonlybyqualieddealershippersonnel,
strictlycomplyingwiththeinstructionsgiven,andusing,wheneverpossible,thespecialtools.
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
shallberesponsibleforanysubsequentdamages.
Themanufacturerandalltheorganizationsofitsdistributionchain,including-withoutlimitation-national,regional,or
localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanu-
facturer,includingthoseusedfortheservicingorrepairoftheproductmanufacturedormarketedbythemanufacturer.
Inanycase,nowarrantyisgivenorattributedontheproductmanufacturedormarketedbythemanufacturerincase
ofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer.
Theinformationinthismanualisup-to-dateatthedateofthepublication.Itisthepolicyofthemanufacturerfor
continuousimprovement.Someinformationcouldnotbeupdatedduetomodicationsofatechnicalorcommercial
type,orchangestothelawsandregulationsofdifferentcountries.
Incaseofquestions,refertoyourNEWHOLLANDAGRICULTURESalesandServiceNetworks.
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INTRODUCTION
Basicinstructions-Shopandassembly
Shimming
Foreachadjustmentoperation,selectadjustingshimsandmeasureindividuallyusingamicrometer,thenaddup
therecordedvalues.Donotrelyonmeasuringtheentireshimmingset,whichmaybeincorrect,ortheratedvalue
indicatedoneachshim.
Rotatingshaftseals
Forcorrectrotatingshaftsealinstallation,proceedasfollows:
•Beforeassembly,allowthesealtosoakintheoilitwillbesealingforatleastthirtyminutes.
•Thoroughlycleantheshaftandcheckthattheworkingsurfaceontheshaftisnotdamaged.
•Positionthesealinglipfacingtheuid;withhydrodynamiclips,takeintoconsiderationtheshaftrotationdirection
andpositionthegroovessothattheywilldeviatetheuidtowardstheinnersideoftheseal.
•Coatthesealinglipwithathinlayeroflubricant(useoilratherthangrease)andllthegapbetweenthesealinglip
andthedustlipondoublelipsealswithgreaseunlessinstructedotherwise.
•Insertthesealinitsseatandpressdownusingaatpunchorsealinstallationtool.Donottapthesealwitha
hammerormallet.
•Whileinsertingtheseal,checkthatitisperpendiculartotheseat;oncesettled,makesurethatitmakescontact
withthethrustelement,ifrequired.
•Topreventdamagingtheseallipontheshaft,positionaprotectiveguardduringinstallationoperations.
O-ringseals
LubricatetheO-ringsealsbeforeinsertingthemintheseats,thiswillpreventthemfromoverturningandtwisting,
whichwouldjeopardizesealingefciency.
Sealingcompounds
Applyoneofthefollowingsealingcompoundsonthematingsurfaceswhenspecied:SILMATE®RTV1473,or
LOCTITE®RTV598orLOCTITE®INSTANTGASKET587BLUE.Beforeapplyingthesealingcompound,preparethe
surfacesasdirectedonproductcontainerorasfollows:
•Removeanyincrustationsusingametalbrush.
•Thoroughlyde-greasethesurfacesusingalocallyapprovedcleaningagentsuchassafetysolventorbrakeparts
cleaner.
Spareparts
Onlyuse"CNHOriginalParts"or"NEWHOLLANDAGRICULTUREParts".
Onlygenuinesparepartsguaranteethesamequality,durationandsafetyasoriginalparts,astheyarethe
samepartsthatareassembledduringstandardproduction.Only"CNHOriginalParts"or"NEWHOLLAND
AGRICULTUREParts"canofferthisguarantee.
Whenorderingspareparts,alwaysprovidethefollowinginformation:
•Machinemodel(commercialname)andserialnumber
•Partnumberoftheorderedpart,whichcanbefoundinthe"ServicePartsCatalogue",usedfororderprocessing
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INTRODUCTION
Protectingtheelectrical/electronicsystemsduringchargingorwelding
WARNING
Batteryacidcausesburns.Batteriescontainsulfuricacid.
Avoidcontactwithskin,eyesorclothing.Antidote(external):Flushwithwater.Antidote(eyes):ush
withwaterfor15minutesandseekmedicalattentionimmediately.Antidote(internal):Drinklarge
quantitiesofwaterormilk.Donotinducevomiting.Seekmedicalattentionimmediately.
Failuretocomplycouldresultindeathorseriousinjury.W0111A
Toavoiddamagetotheelectronic/electricalsystems,alwaysobservethefollowing:
1.Nevermakeorbreakanyofthechargingcircuitconnections,includingthebatteryconnections,whentheengine
isrunning.
2.Nevershortanyofthechargingcomponentstoground.
3.Alwaysdisconnectthegroundcablefromthebatterybeforearcweldingonthemachineoronanyattachments
onthemachine.
•Positiontheweldergroundclampasclosetotheweldingareaaspossible
•Ifweldingincloseproximitytoacomputermodule,thenthemoduleshouldberemovedfromthemachine
•Neverallowweldingcablestolayon,nearoracrossanyelectricalwiringorelectroniccomponentwhilewelding
isinprogress
4.Alwaysdisconnectthenegativecablefromthebatterywhenchargingthebatteryinthemachinewithabattery
charger.
NOTICE:Ifweldingmustbeperformedontheunit,thebatterygroundcablemustbedisconnectedfromthemachine
battery.Theelectronicmonitoringsystemandchargingsystemwillbedamagedifthisisnotdone.
Removethebatterygroundcable.Reconnectthecablewhenweldingiscompleted.
Tools
ThetoolsthatNEWHOLLANDAGRICULTUREsuggestsandillustratedinthismanualhavebeen:
•SpecicallyresearchedanddesignedforusewithNEWHOLLANDAGRICULTUREmachines
•Essentialforreliablerepairoperations
•Accuratelybuiltandrigorouslytestedsoastoofferefcientandlong-lastingoperation
Byusingthesetools,repairpersonnelwillbenetfrom:
•Operatinginoptimaltechnicalconditions
•Obtainingthebestresults
•Savingtimeandeffort
•Workinginsafeconditions
NOTE:Theterms"front","rear","right-hand"and"left-hand"(whenreferredtodifferentparts)aredeterminedfrom
therear,facinginthedirectionoftravelofthemachineduringoperation.
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INTRODUCTION
Torque-Minimumtighteningtorquesfornormalassembly
METRICNON-FLANGEDHARDWARE
NOM.
SIZE
CLASS8.8BOLTand
CLASS8NUT
CLASS10.9BOLTand
CLASS10NUT
LOCKNUT
CL.8
W/CL8.8
BOLT
LOCKNUT
CL.10
W/CL10.9
BOLT
UNPLATEDPLATED
W/ZnCrUNPLATEDPLATED
W/ZnCr
M42.2N·m(19lb
in)
2.9N·m(26lb
in)
3.2N·m(28lb
in)
4.2N·m(37lb
in)2N·m(18lbin)2.9N·m(26lb in)
M54.5N·m(40lb
in)
5.9N·m(52lb
in)
6.4N·m(57lb
in)
8.5N·m(75lb
in)4N·m(36lbin)5.8N·m(51lb in)
M67.5N·m(66lb
in)
10N·m(89lb
in)
11N·m(96lb
in)
15N·m(128lb
in)
6.8N·m(60lb
in)
10N·m(89lb
in)
M818N·m(163lb
in)
25N·m(217lb
in)
26N·m(234lb
in)
35N·m(311lb
in)
17N·m(151lb
in)
24N·m(212lb
in)
M1037N·m(27lbft)49N·m(36lb
ft)52N·m(38lbft)70N·m(51lb ft)
33N·m(25lb
ft)
48N·m(35lb
ft)
M1264N·m(47lbft)85N·m(63lb
ft)91N·m(67lbft)121N·m(90lb ft)
58N·m(43lb
ft)
83N·m(61lb
ft)
M16158N·m(116lb
ft)
210N·m(155
lbft)
225N·m(166lb
ft)
301N·m(222
lbft)
143N·m(106lb
ft)
205N·m(151lb
ft)
M20319N·m(235lb
ft)
425N·m(313
lbft)
440N·m(325lb
ft)
587N·m(433
lbft)
290N·m(214lb
ft)
400N·m(295lb
ft)
M24551N·m(410lb
ft)
735N·m(500
lbft)
762N·m(560lb
ft)
1016N·m(750
lbft)
501N·m(370lb
ft)
693N·m(510lb
ft)
NOTE:M4throughM8hardwaretorquespecicationsareshowninpound-inches.M10throughM24hardwaretorque
specicationsareshowninpound-feet.
IDENTIFICATION
MetricHexheadandcarriagebolts,classes5.6andup
200836801
1.Manufacturer'sIdentication
2.PropertyClass
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INTRODUCTION
MetricHexnutsandlocknuts,classes05andup
200836812
1.Manufacturer'sIdentication
2.PropertyClass
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INTRODUCTION
3.ClockMarkingofPropertyClassandManufacturer'sIdentication(Optional),i.e.marks60°apartindicateClass
10properties,andmarks120°apartindicateClass8.
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INTRODUCTION
Torque-Standardtorquedataforhydraulics
STANDARDTORQUEDATAFORHYDRAULICTUBESANDFITTINGS
NOTICE:AllhydraulicttingsonthismachineareBritishStandardPipeThread(BSP).thesettingsareNOTinter-
changeablewithNationalPipeThread(NPT).SeeyourauthorizedNEWHOLLANDAGRICULTUREdealerforthe
correctttlngsoradapters.
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INTRODUCTION
Generalspecication-GeneralWelding
WARNING
Explosionhazard!
Batteriesemitexplosivegases.Alwaysventilatewhenusinginanenclosedareaorwhencharging.
Keepthebatteryawayfromsparks,openames,andotherignitionsources.
Failuretocomplycouldresultindeathorseriousinjury.W0369A
Usea7013or7011weldingrodorwirethatmeetsthefollowingAmericanWeldingSociety(AWS)specications:
ER80S-D2,ER70S-6orE70C-M6-H4.
NOTICE:ALWAYSdisconnectthebattery(bothterminals)beforeweldingonanypartofthemachine.Failuretodo
somaycausedamagetosensitiveelectricalcomponents.
NOTICE:Locatetheweldinggroundascloseaspossibletotheareatobewelded.Donotallowthegroundcurrent
topassthroughanyrollertypebearing.Arcinginsidetherollerbearingcanresultinseveremachinedamage.
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SERVICEMANUAL
Maingearboxanddrive
MegaCutter™512
MegaCutter™530
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Contents
Maingearboxanddrive-14
[14.100]Maingearboxanddrive..............................................................14.1
MegaCutter™512,MegaCutter™530
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Maingearboxanddrive-14
Maingearboxanddrive-100
MegaCutter™512
MegaCutter™530
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Contents
Maingearboxanddrive-14
Maingearboxanddrive-100
SERVICE
Maingearboxanddrive
Serviceinstruction-Howtochangegearboxshaftrotation.......................................3
MegaCutter™512
ChangeuidMaingearoil...................................................................6
MegaCutter™512
Check–Oillevel...........................................................................7
MegaCutter™512
ChangeuidBevelgearoil..................................................................8
MegaCutter™512
Check-Maingearoillevel..................................................................9
MegaCutter™530
Drainuid–Maingearoilchange...........................................................10
MegaCutter™530
Check-Bevelgearoillevel.................................................................11
MegaCutter™530
Drainuid-Bevelgearoilchange...........................................................12
MegaCutter™530
Maingearbox
Replace-V-belt..........................................................................13
MegaCutter™530
Disassemble.............................................................................14
MegaCutter™530
Assemble................................................................................17
MegaCutter™530
Disassemble.............................................................................20
MegaCutter™512
Assemble................................................................................22
MegaCutter™512
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Maingearboxanddrive-Maingearboxanddrive
Maingearboxanddrive-Serviceinstruction-Howtochange
gearboxshaftrotation
MegaCutter™512
Themachineisequippedwithamaindrivegearboxthat
allowsittobeinstalledontractorswithbothclockwiseand
counter-clockwiserotatingfrontPTOshafts.Bydefault,the
unitisshippedconguredforusewithtractorshavinga
counterclockwiserotatingPTO,asdepictedinthegure.
Thedirectionofrotationisdeterminedbylookingtoward
thetractor’sPTOshaft.Fortractorswithclockwiserotating
frontPTOshafts,thegearboxwillneedtoberemovedand
convertedbeforethePTOshaftisinstalled.
NHIL12HT00106AA1
1.RemovethePTOhousingshield(1).
NHIL12HT00226AA2
2.Removethesupportbolts(1).
NHIL12HT00108AA3
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Maingearboxanddrive-Maingearboxanddrive
3.Removethebolts(1)onthebracket.
NHIL12HT00226AA4
4.Removethegearbox(1)fromthemachineandplace
itinthepositionshown.
NHIL12HT00109AA5
5.Removethebreather(1)andtheoildrainplug(2)
andswitchthem.
NHIL12HT00110AA6
NHIL12HT00111AA7
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