New Holland FR450, FR500, FR600, FR700, FR850 Service Manual

SERVICE MANUAL FR 47812460 09/01/2015 EN

Link Product / Engine Product Market Product Engine FR850 FR850 TIER 2 [5803 - ] Europe FVAE2884X*B200 FR450 FR450 TIER 4A [5803 - ] Europe F2CFE613A*A FR500 FR500 TIER 4A [5803 - ] Europe F3BFE613E*A FR600 FR600 TIER 3 [5803 - ] Europe F3CE0684E*E920 47812460 09/01/2015

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase ............................................................. 10.1 [10.218] Fuel injection system ............................................................... 10.2 [10.400] Engine cooling system ............................................................. 10.3 [10.414] Fan and drive ...................................................................... 10.4 [10.418] Rotary screen ...................................................................... 10.5 Main gearbox and drive ............................................................... 14 [14.100] Main gearbox and drive ............................................................ 14.1 Transmission.............................................................................. 21 [21.114] Mechanical transmission ........................................................... 21.1 [21.120] Gearbox ............................................................................ 21.2 [21.130] Mechanical transmission external controls ......................................... 21.3 [21.100] Mechanical transmission lubrication system ....................................... 21.4 [21.145] Gearbox internal components ...................................................... 21.5 [21.182] Differential .......................................................................... 21.6 Four-Wheel Drive (4WD) system .................................................. 23 [23.101] Mechanical control ................................................................. 23.1 [23.304] Four-Wheel Drive (4WD) gearbox ................................................. 23.2 Front axle system ....................................................................... 25 [25.100] Powered front axle ................................................................. 25.1 [25.102] Front bevel gear set and differential ............................................... 25.2 [25.310] Final drives ......................................................................... 25.3 Rear axle system ........................................................................ 27 [27.450] Rear-powered steerable axle ...................................................... 27.1 [27.550] Non-powered rear axle ............................................................. 27.2 47812460 09/01/2015

Hydrostatic drive ......................................................................... 29 [29.100] Transmission and steering hydrostatic control ..................................... 29.1 [29.218] Pump and motor components ...................................................... 29.2 [29.202] Hydrostatic transmission ........................................................... 29.3 Brakes and controls .................................................................... 33 [33.202] Hydraulic service brakes ........................................................... 33.1 [33.110] Parking brake or parking lock ...................................................... 33.2 Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems .................................................................. 35.1 [35.106] Variable displacement pump ....................................................... 35.2 [35.204] Remote control valves ............................................................. 35.3 [35.300] Reservoir, cooler, and filters........................................................ 35.4 [35.359] Main control valve .................................................................. 35.5 [35.350] Safety and main relief valves ...................................................... 35.6 [35.600] High flow hydraulics ................................................................ 35.7 [35.410] Header or attachment height system .............................................. 35.8 [35.602] Header or attachment leveling system ............................................. 35.9 [35.514] Upper feed roll gearbox system .................................................. 35.10 [35.516] Cutterhead drive system ......................................................... 35.11 [35.530] Spout rotation circuit ............................................................. 35.12 [35.532] Spout raising system ............................................................. 35.13 [35.534] Spout deflector system ........................................................... 35.14 Steering..................................................................................... 41 [41.101] Steering control .................................................................... 41.1 [41.200] Hydraulic control components...................................................... 41.2 [41.206] Pump ............................................................................... 41.3 [41.216] Cylinders ........................................................................... 41.4 [41.432] Autoguidance steering ............................................................. 41.5 47812460 09/01/2015

Wheels ...................................................................................... 44 [44.511] Front wheels........................................................................ 44.1 [44.520] Rear wheels ........................................................................ 44.2 Cab climate control ..................................................................... 50 [50.100] Heating ............................................................................. 50.1 [50.200] Air conditioning ..................................................................... 50.2 Electrical systems ....................................................................... 55 [55.000] Electrical system ................................................................... 55.1 [55.100] Harnesses and connectors ......................................................... 55.2 [55.015] Engine control system.............................................................. 55.3 [55.010] Fuel injection system ............................................................... 55.4 [55.014] Engine intake and exhaust system................................................. 55.5 [55.988] Selective Catalytic Reduction (SCR) electrical system ............................ 55.6 [55.012] Engine cooling system ............................................................. 55.7 [55.013] Engine oil system .................................................................. 55.8 [55.512] Cab controls ........................................................................ 55.9 [55.640] Electronic modules ............................................................... 55.10 [55.610] Ground speed control ............................................................ 55.11 [55.019] Hydrostatic drive control system ................................................. 55.12 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................. 55.13 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system............... 55.14 [55.421] Feeding control system .......................................................... 55.15 [55.800] Metal detector .................................................................... 55.16 [55.820] Chopping and cutting control systems ........................................... 55.17 [55.830] Rotary screen drive and cleaning ................................................ 55.18 [55.680] Autopilot/Autoguidance .......................................................... 55.19 [55.450] Ejecting control system .......................................................... 55.20 [55.408] Warning indicators, alarms, and instruments .................................... 55.21 47812460 09/01/2015

Attachments/Headers .................................................................. 58 [58.900] Belt feeding ........................................................................ 58.1 Product feeding .......................................................................... 60 [60.103] Lower feed rolls .................................................................... 60.1 [60.107] Upper feed rolls .................................................................... 60.2 [60.155] Metal detector ...................................................................... 60.3 Chopping ................................................................................... 64 [64.100] Cutterhead ......................................................................... 64.1 [64.106] Drum ............................................................................... 64.2 [64.130] Drum gearbox ...................................................................... 64.3 [64.140] Sharpening system................................................................. 64.4 [64.150] Shearbar ........................................................................... 64.5 [64.160] Crop processor ..................................................................... 64.6 [64.170] Transition channel/concave and lever ............................................. 64.7 Ejection ..................................................................................... 70 [70.120] Blower .............................................................................. 70.1 [70.140] Spout ............................................................................... 70.2 Platform, cab, bodywork, and decals ............................................. 90 [90.105] Machine shields and guards ....................................................... 90.1 [90.150] Cab ................................................................................. 90.2 47812460 09/01/2015

INTRODUCTION 47812460 09/01/2015 1

Contents INTRODUCTION Basic instructions - How to use and navigate through this Manual ............................. 3 Advice ......................................................................................... 10 Note to the Owner (*) ......................................................................... 11 Safety rules ................................................................................... 12 Safety rules - Ecology and the environment .................................................. 13 Safety rules ................................................................................... 14 Personal safety ............................................................................... 17 Basic instructions - Shop and assembly ...................................................... 18 Torque ........................................................................................ 20 Basic instructions - Chain Wear Tables - Roller Chains ...................................... 22 Conversion factors ............................................................................ 24 General specification System protection data ................................................ 25 Product identification .......................................................................... 28 (*) See content for specific models 47812460 09/01/2015 2

INTRODUCTION Basic instructions - How to use and navigate through this Manual Technical information This manual has been produced by a new technical information system. This new system is designed to deliver technical information electronically through Web delivery (eTim), DVD and in paper manuals. A coding system called SAP has been developed to link the technical information to other Product Support functions, e.g., Warranty. Technical information is written to support the maintenance and service of the functions or systems on a customer's machine. When a customer has a concern on his machine it is usually because a function or system on his machine is not working at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the technical information in this manual to resolve that customer's concern, you will find all the information classified using the SAP coding, according to the functions or systems on that machine. Once you have located the technical information for that function or system then you will find all the mechanical, electrical or hydraulic devices, components, assemblies and sub assemblies for that function or system. You will also find all the types of information that have been written for that function or system, the technical data (specifications), the functional data (how it works), the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.). By integrating SAP coding into technical information, you will be able to search and retrieve just the right piece of technical information you need to resolve that customer's concern on his machine. This is made possible by attaching 3 categories to each piece of technical information during the authoring process. The first category is the Location, the second category is the Information Type and the third category is the Product: • LOCATION - is the component or function on the machine, that the piece of technical information is going to describe e.g. Fuel tank. • INFORMATION TYPE - is the piece of technical information that has been written for a particular component or function on the machine e.g. Capacity would be a type of Technical Data that would describe the amount of fuel held by the Fuel tank. • PRODUCT - is the model for which the piece of technical information is written. Every piece of technical information will have those 3 categories attached to it. You will be able to use any combination of those categories to find the right piece of technical information you need to resolve that customer's concern on his machine. That information could be: • the description of how to remove the cylinder head • a table of specifications for a hydraulic pump • a fault code • a troubleshooting table • a special tool 47812460 09/01/2015 3

New Holland FR450, FR500, FR600, FR700, FR850 Service Manual

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