New Holland H8040 Self-Propelled Windrower Service Repair Manual

Part number 47487694 1st edition English January 2013 SERVICE MANUAL H8040 Self-Propelled Windrower from PIN YCG667001 and above

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase ............................................................. 10.1 [10.202] Air cleaners and lines .............................................................. 10.2 [10.216] Fuel tanks .......................................................................... 10.3 [10.218] Fuel injection system ............................................................... 10.4 [10.254] Intake and exhaust manifolds and mufﬂer ......................................... 10.5 [10.400] Engine cooling system ............................................................. 10.6 Front axle system ....................................................................... 25 [25.310] Final drives ......................................................................... 25.1 Rear axle system ........................................................................ 27 [27.550] Non-powered rear axle ............................................................. 27.1 Hydrostatic drive ......................................................................... 29 [29.100] Transmission and steering hydrostatic control ..................................... 29.1 [29.202] Hydrostatic transmission ........................................................... 29.2 [29.218] Pump and motor components ...................................................... 29.3 Power Take-Off (PTO) ................................................................. 31 [31.226] Hydraulic pump drive ............................................................... 31.1 Brakes and controls .................................................................... 33 [33.110] Parking brake / Parking lock ....................................................... 33.1 Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems .................................................................. 35.1 [35.102] Pump control valves................................................................ 35.2 [35.104] Fixed displacement pump .......................................................... 35.3 [35.105] Charge pump ....................................................................... 35.4 [35.300] Reservoir, cooler, and ﬁlters........................................................ 35.5 47487694 17/01/2013

[35.565] Cutter control circuit ................................................................ 35.6 [35.910] Draper header hydraulic drive...................................................... 35.7 Steering..................................................................................... 41 [41.101] Steering control .................................................................... 41.1 Wheels ...................................................................................... 44 [44.520] Rear wheels ........................................................................ 44.1 Cab climate control ..................................................................... 50 [50.100] Heating ............................................................................. 50.1 [50.104] Ventilation .......................................................................... 50.2 [50.200] Air conditioning ..................................................................... 50.3 Electrical systems ....................................................................... 55 [55.000] Electrical system ................................................................... 55.1 [55.010] Fuel injection system ............................................................... 55.2 [55.013] Engine oil system .................................................................. 55.3 [55.014] Engine intake and exhaust system................................................. 55.4 [55.015] Engine control system.............................................................. 55.5 [55.019] Hydrostatic drive control system ................................................... 55.6 [55.031] Parking brake electrical system .................................................... 55.7 [55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system................. 55.8 [55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls................... 55.9 [55.100] Harnesses and connectors ....................................................... 55.10 [55.201] Engine starting system ........................................................... 55.11 [55.404] External lighting .................................................................. 55.12 [55.512] Cab controls ...................................................................... 55.13 [55.518] Wiper/Washer system ............................................................ 55.14 [55.520] Cab harvesting controls .......................................................... 55.15 [55.634] Merger electrical control system ................................................. 55.16 [55.661] Cab header controls.............................................................. 55.17 47487694 17/01/2013

[55.662] Header height control ............................................................ 55.18 [55.830] Rotary screen drive and cleaning ................................................ 55.19 [55.DTC] FAULT CODES .................................................................. 55.20 Attachments/Headers .................................................................. 58 [58.110] Attachment/Header cutting mechanism ............................................ 58.1 Platform, cab, bodywork, and decals ............................................. 90 [90.124] Pneumatically-adjusted operator seat.............................................. 90.1 [90.150] Cab ................................................................................. 90.2 [90.151] Cab interior ......................................................................... 90.3 [90.154] Cab doors and hatches ............................................................ 90.4 47487694 17/01/2013

INTRODUCTION 47487694 17/01/2013 1

Contents INTRODUCTION Basic instructions - Important notice regarding equipment servicing ........................... 3 [YCG667001-], H8040 Note to the Owner .............................................................................. 4 Safety rules ..................................................................................... 5 Safety rules ..................................................................................... 6 [YCG667001-], H8040 Foreword - Ecology and the environment .................................................... 14 H8000 Personal safety - Do not operate tag ......................................................... 15 Safety rules ................................................................................... 16 Torque - Minimum tightening torques for normal assembly ................................... 17 Torque - Standard torque data for hydraulics ................................................. 21 Basic instructions - Shop and assembly ...................................................... 23 Basic instructions - Hydraulic contamination ................................................. 25 [YCG667001-] General specification ......................................................................... 26 [YCG667001-] Capacities ..................................................................................... 29 [YCG667001-] General specification - Biodiesel Fuels ....................................................... 30 Product identification .......................................................................... 31 [YCG667001-] Product overview - Machine orientation ...................................................... 32 [YCG667001-] 47487694 17/01/2013 2

INTRODUCTION Basic instructions - Important notice regarding equipment servicing [YCG667001-], H8040 All repair and maintenance work listed in this manual must be carried out only by qualiﬁed dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modiﬁcations of a technical or commercial type, or changes to the laws and regulations of different countries. In case of questions, refer to your NEW HOLLAND AGRICULTURE Sales and Service Networks. 47487694 17/01/2013 3

INTRODUCTION Note to the Owner COMPANY POLICY Company policy, which is one of continuous improvement, reserves the right to make changes in design and specifi- cations at any time without notice and without obligation to modify units previously built. All data given in this book is subject to production variations. Dimensions and weights are approximate only and the illustrations do not necessarily show windrowers in standard condition. PARTS AND ACCESSORIES Genuine NEW HOLLAND AGRICULTURE parts and accessories have been specifically designed for NEW HOLLAND AGRICULTURE MACHINES. We would like to point out those "NON-GENUINE" parts and accessories have not been examined and released by NEW HOLLAND AGRICULTURE. The installation and or use of such products could have negative effects upon the design characteristics of your machine and thereby affect its safety. NEW HOLLAND AGRICULTURE is not liable for any damage caused by the use of "NON-GENUINE" NEW HOLLAND AGRICULTURE parts and accessories. LUBRICATION Adequate lubrication and maintenance on a regular schedule is vital to maintaining your equipment. To ensure long service and efficient operation, follow the lubrication and maintenance schedules outlined in this manual. The use of proper fuels, oils, grease and filters, as well as keeping the systems clean, will also extend machine and component life. NOTICE: Always use genuine NEW HOLLAND AGRICULTURE replacement parts, oils and filters to ensure proper operation, filtration of engine and hydraulic systems. See your NEW HOLLAND AGRICULTURE dealer for additional oil quantities. 47487694 17/01/2013 4

INTRODUCTION Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury. Throughout this manual you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine. DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety. Information NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage. 47487694 17/01/2013 5

INTRODUCTION Safety rules [YCG667001-], H8040 General safety rules Use caution when operating the machine on slopes. Raised equipment, full tanks and other loads will change the center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven surfaces. Never permit anyone other than the operator to ride on the machine. Never operate the machine under the influence of alcohol, drugs, or while otherwise impaired. When digging or using ground engaging attachments be aware of buried cables. Contact local utilities to determine the locations of services. Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance for safety. Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection. • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper. • Stop engine, remove key and relieve the pressure before connecting or disconnecting fluid lines. • Make sure all components are in good condition and tighten all connections before starting the engine or pressur- izing the system. • If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately. • Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the skin promptly with soap and water. Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become entangled in moving parts. Wear protective equipment when appropriate. DO NOT attempt to remove material from any part of the machine while it is being operated or components are in motion. Make sure all guards and shields are in good condition and properly installed before operating the machine. Never operate the machine with shields removed. Always close access doors or panels before operating the machine. Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and clear of debris. A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO NOT allow anyone to enter the work area. Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter the area underneath raised equipment during operation. Never operate engine in enclosed spaces as harmful exhaust gases may build up. Before starting the machine, be sure that all controls are in neutral or park lock position. Start the engine only from the operator’s seat. If the safety start switch is bypassed, the engine can start with the transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as described in the manual. Starting in gear may cause death or serious injury. Always keep windows, mirrors, all lighting, and Slow Moving Vehicle (SMV) emblem clean to provide the best possible visibility while operating the machine. Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from other locations. 47487694 17/01/2013 6

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New Holland H8040 Self-Propelled Windrower Service Repair Manual

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