New Holland FR480 Forage Cruiser Service Manual
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New Holland FR480 Forage Cruiser Service Manual

Forage harvester
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SERVICE MANUAL
FR480 Forage Cruiser / FR550 Forage Cruiser /
FR650 Forage Cruiser / FR780 Forage Cruiser
FR480 Forage Cruiser - From PIN 715912001 to 715923100
FR550 Forage Cruiser - From PIN 725912001 to 725923100
FR650 Forage Cruiser - From PIN 735912001 to 735923100
FR780 Forage Cruiser - From PIN 745912001 to 745923100
FR850 Forage Cruiser - From PIN 555912001 to 555923100
Part number 48142788
English
April 2017
Tier 4B (final)
Forage Harvester
FR850 Forage Cruiser
Tier 2
Forage Harvester

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Summary of Contents for New Holland FR480 Forage Cruiser

  • Page 1 FR650 Forage Cruiser / FR780 Forage Cruiser Tier 4B (final) Forage Harvester FR480 Forage Cruiser - From PIN 715912001 to 715923100 FR550 Forage Cruiser - From PIN 725912001 to 725923100 FR650 Forage Cruiser - From PIN 735912001 to 735923100 FR780 Forage Cruiser - From PIN 745912001 to 745923100...
  • Page 2 SERVICE MANUAL FR480 Forage Cruiser Cursor 13, TIER 4B (FINAL) [715912001 - 715923100] FR550 Forage Cruiser Cursor 13, TIER 4B [725912001 - 725923100] FR650 Forage Cruiser Cursor 16, TIER 4B (FINAL) [735912001 - 735923100] FR780 Forage Cruiser Cursor 16, TIER 4B (FINAL) [745912001 - 745923100]...
  • Page 3 Link Product / Engine Product Market Product Engine FR480 Forage Cruiser Cursor 13, North America F3HFE613H*B007 TIER 4B (FINAL) [715912001 - 715923100] FR550 Forage Cruiser Cursor 13, North America F3H FE613F*B007 TIER 4B [725912001 - 725923100] FR650 Forage Cruiser Cursor 16,...
  • Page 4 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.216] Fuel tanks .
  • Page 5 Rear axle system................ 27 [27.450] Rear-powered steerable axle ............27.1 [27.550] Non-powered rear axle .
  • Page 6 [41.101] Steering control ..............41.1 [41.206] Pump .
  • Page 7 [55.820] Chopping and cutting control systems ......... . . 55.18 [55.830] Rotary screen drive and cleaning .
  • Page 8 Lubrication system ..............71 [71.460] Grease lubrication system ............71.1 Platform, cab, bodywork, and decals ..........
  • Page 9 48142788 28/04/2017 Find manuals at https://best-manuals.com...
  • Page 10 INTRODUCTION 48142788 28/04/2017 Find manuals at https://best-manuals.com...

  • Page 11: Table Of Contents

    Contents INTRODUCTION Basic instructions - How to use and navigate through this Manual (*) ......3 Foreword - Important notice regarding equipment servicing (*) .

  • Page 12: Basic Instructions - How To Use And Navigate Through This Manual

    INTRODUCTION Basic instructions - How to use and navigate through this Manual FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser 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.
  • Page 13 INTRODUCTION How to use this manual This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at the end of a Chapter.
  • Page 14 INTRODUCTION 63 - Chemical applicators 64 - Chopping 66 - Threshing 68 - Tying/Wrapping/Twisting 69 - Bale wagons 70 - Ejection 71 - Lubrication system 72 - Separation 73 - Residue handling 74 - Cleaning 75 - Soil preparation/Finishing 76 - Secondary cleaning / Destemmer 77 - Seeding 78 - Spraying 79 - Planting...
  • Page 15 INTRODUCTION Section contents Section Number Description Maintenance Machine completion and equipment Engine Main gearbox and drive Clutch Transmission Four wheel drive system Front axle system Rear axle system Hydrostatic drive Implement power take-off Brakes and controls This Section covers the central parts of the hydraulic system.
  • Page 16 INTRODUCTION Number Description Section Telescopic single arm Booms, dippers and buckets Dozer blade and arm Accessories Tools This Section covers all the main functions and systems related to the body of the machine, including the Platform, cab, bodywork and decals operators cab and the platform.
  • Page 17 INTRODUCTION Chapters Each Chapter is identified by a number e.g. Hydraulic Systems - Main check valve- 35.359. The first number is identical to the Section number i.e. Chapter 35.359 is inside Section 35, Hydraulic Systems. The second number is representative of the Chapter contained within the Section. CONTENTS The Chapter Contents lists all the technical data (specifications), functional data (how it works), service data (remove, install adjust, etc..) and diagnostic data (fault codes and troubleshooting) that have been written in that Chapter for...
  • Page 18 INTRODUCTION Information units and information search Each chapter is composed of information units. Each information unit has a page reference within that Chapter. The information units provide a quick and easy way to find just the right piece of technical information you are looking for. Example information unit Main control valve - Sectional View (35.359) Information Unit SAP code...

  • Page 19: Foreword - Important Notice Regarding Equipment Servicing

    Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice. In case of questions, refer to your NEW HOLLAND Sales and Service Networks. 48142788 28/04/2017...

  • Page 20: Note To The Owner

    INTRODUCTION Note to the Owner FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser Engine repair information: The engine repair information is not contained within this manual. For engine repair information, please refer to the respective Service Manual for the engine type used in your vehicle.

  • Page 21: Safety Rules - Ecology And The Environment

    Improper disposal of batteries can contaminate the soil, groundwater, and waterways. NEW HOLLAND strongly recommends that you return all used batteries to a NEW HOLLAND dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

  • Page 22: Safety Rules

    INTRODUCTION Safety rules FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser LEGAL OBLIGATIONS This machine may be equipped with special guarding or other devices in compliance with local legislation. Some to these require active use by the operator. Therefor, check local legislations on the usage of this machine.
  • Page 23 INTRODUCTION • Do not carry out repair operations with someone sitting in the driver's seat, unless the person is a trained technician who is assisting with the operation in question. • Do not operate the machine or use any of the implements from different positions, other than the driver's seat. •...
  • Page 24 INTRODUCTION Machine start-up. • Never run the engine in confined spaces that are not equipped with adequate ventilation for exhaust gas extraction. • Never place the head, body, limbs, feet, hands or fingers near rotating and moving parts. Hydraulic systems and fuel injection systems •...

  • Page 25: Personal Safety

    INTRODUCTION Personal safety FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser WARNING Heavy object! ALWAYS use a hoist or get assistance to lift the component. Failure to comply could result in death or serious injury.

  • Page 26: Basic Instructions - Shop And Assembly

    Only use CNH Original Parts or NEW HOLLAND Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts or NEW HOLLAND Original Parts can offer this guarantee.
  • Page 27 W0111A Special tools The special tools that NEW HOLLAND suggests and illustrate in this manual have been specifically researched and designed for use with NEW HOLLAND machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting operation.

  • Page 28: Torque

    INTRODUCTION Torque FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser Minimum hardware tightening torques (in N m or lb in /lb ft) for normal assembly applica- tions unless otherwise stated NOTICE: Shown below is the suggested initial torque tightening sequences for general applications, tighten in se- quence from item 1 through to the last item of the hardware.
  • Page 29 INTRODUCTION Class 8.8 in N m (lb in or lb ft) Class 10.9 in N m (lb in or lb ft) Nominal Plated nut Lock nut Hardened nut Plated nut Lock nut Hardened nut Size 1073 N·m 590.1 N·m 967.5 N·m 1486 N·m 817.3 N·m 1337 N·m...
  • Page 30 INTRODUCTION ZEIL06CS0135F0A 48142788 28/04/2017...

  • Page 31: Torque - Standard Torque Data For Hydraulic Connections

    Over-torquing of a hydraulic connection can also lead to leakage or failure. For some connections, NEW HOLLAND requires a different torque value than is listed in the ISO and SAE standards. • The torque values in this document should be used whenever possible or applicable.
  • Page 32 INTRODUCTION Torque values for metric O-Ring Boss (ORB) port connections S-Series * L-Series ** Metric Ferrous Non-Ferrous Ferrous Non-Ferrous thread N·m (lb ft) ± 10% N·m (lb ft) ± 10% N·m (lb ft) ± 10% N·m (lb ft) ± 10% M8 x 1 10.5 (7.7) 6.3 (4.6)
  • Page 33 INTRODUCTION Torque values for port connections (British Standard Pipe Parallel (BSPP) thread ports and stud ends) Metric tube Outside Diameter (OD) Ferrous Non-Ferrous mm (in) BSPP S-Series L-Series S-Series L-Series thread S-Series * L-Series ** N·m (lb ft) N·m (lb ft) N·m (lb ft) N·m (lb ft) G- Gas;...
  • Page 34 INTRODUCTION Torque values for Inch O-Ring Boss (ORB) port non-adjustable connections S-Series * L-Series ** Ferrous Non- Ferrous Non- Inch tube UN/UNF N·m (lb ft) Ferrous N·m (lb ft) Ferrous dash size thread size ± 10% N·m (lb ft) ± 10% N·m (lb ft) mm (in) ±...
  • Page 35 INTRODUCTION Torque values for inch O-Ring Boss (ORB) port plugs Ferrous Non-Ferrous Internal hex External hex UN/UNF N·m (lb ft) N·m (lb ft) N·m (lb ft) dash size thread size ± 10% ± 10% ± 10% 5/16-24 7.5 (5.5) 12.5 (9.2) 7.5 (5.5) 3/8-24 14.5 (10.7)
  • Page 36 INTRODUCTION Torque values for four-bolt flange connections (Inch Screws, Grade 8) Code 61 Code 62 Metric size Imperial size Screw code Screw code N·m (lb ft) N·m (lb ft) ± 10% ± 10% 5/16-18 34 (25.1) 5/16-18 34 (25.1) 3/8-16 63 (46.5) 3/8-16 63 (46.5)
  • Page 37 INTRODUCTION Torque values for O-Ring Face Seals (ORFS) connections Hex size Metric Swivel nut Swivel nut Inch tube (mm) UN/UNF tube dash torque torque OD (mm) (Reference thread size OD (mm) size N·m (lb ft) N·m (lb ft) only) ± 10% ±...

  • Page 38: Basic Instructions - Chain Wear Tables - Roller Chains

    INTRODUCTION Basic instructions - Chain Wear Tables - Roller Chains FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser Chain Wear The individual joints in a roller chain articulate as they enter and leave the sprockets. This articulation results in wear on the pins and bushings.
  • Page 39 INTRODUCTION This relationship is often useful since the normal maximum allowable chain wear elongation of 3% is valid only up to 67 teeth in the large sprocket. In drives having fixed center distances, chains running in parallel or where smoother operation is required, wear should be limited to approximately 1.5%.

  • Page 40: Conversion Factors

    INTRODUCTION Conversion factors FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser Length 1 mm 0.0393 in 1 in 25.4 mm 1 km 0.621 miles 1 miles 1.609 km 0.3048 m 3.281 ft 1 ft...

  • Page 41: Operating Alarms

    INTRODUCTION Operating alarms FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser Alarm list The following is a list of the alarms with the description, explanation, priority, activation and reset measure. Both, description and explanation appears on the monitor if an alarm occur.
  • Page 42 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Feeding request Header brakes are Feeding forward OR reverse A1007 closed. Connect White Time-out disabled AND header brakes header cable closed Forage Control At key on, main At key on, main relay Module (CM) relay is Off Harness problem...
  • Page 43 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description The reel is running too slow. Increase Reel speed too Reel speed < Reel speed > speed OR the A1111 White minimum minimum “header reel flow limit” setting The reel is running too fast.
  • Page 44 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Transition channel “Transition channel door cannot be door open” button is pressed while Operation not opened when the A1207 White Time-out cutterhead speed is allowed engine is running or not 0 or engine is the cutterhead speed is not 0...
  • Page 45 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Operator is not (integrated in state seated OR spout flow diagram. alarm is too low. raises when:) system IntelliFill™ not System enabled A2010 White Also make sure disengaged allowed camera calibration is AND resume button not ongoing.
  • Page 46 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Low pressure in the feed rolls hydrostatic Engine running AND system. Restart engine shutdown A2108 Engine shut off at own risk by Time-out 60 s request from feed holding the throttle rolls pump down switch during cranking...
  • Page 47 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Engine power has Cursor engines: been derated due Cursor engines: Engine power A2118 White temperature ≤ to high intake air temperature > 87 °C derated 87 °C temperature Engine power has Engine power A2119 been derated due to...
  • Page 48 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Invalid parking brake Parking brake Valid parking A2132 valve (short circuit) shut down brake valve The engine data- set registration Engine security value Engine security information was not Engine security A2133 Yellow not received within...
  • Page 49 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description High fuel Engine not temperature. Restart Engine running AND running OR no at own risk by engine shutdown A2211 Engine shut-off engine shutdown holding the throttle request from fuel request from fuel down switch during temperature...
  • Page 50 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Actual pressure Actual pressure > Main clutch pressure < 40 bar AND 40 bar OR desired Main clutch is too high. The desired pressure A3008 pressure = 0 AND pressure high engine will stop = 0 AND actual...
  • Page 51 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description The Temperature of Hydraulic tank the oil tank is too Oil temperature > Oil temperature A3201 Yellow temperature high high. Clean radiator 90 °C < 85 °C and check oil level Hydraulic tank A3202 Add hydraulic oil...
  • Page 52 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Gearbox oil Gearbox oil temperature temperature < 5 °C ≥ 5 °C AND AND hydraulic oil hydraulic oil White temperature < 20 °C temperature AND engine not ≥ 20 °C AND running engine running Gearbox oil...
  • Page 53 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Additives system = Additives system The chosen additives working mode can't enabled AND ≠ enabled OR function. additives working additives working Additives Header width OR mode = area AND mode ≠...
  • Page 54 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Module not detected CM1 not A5000 after power on detected Module has been A5001 communication detected but is lost lost Module not detected CM2 not A5002 after power on detected Module has been A5003...
  • Page 55 INTRODUCTION Prior- Alarm Resetting Alarm Alarm explanation Activation Time Time description Module not detected LCP not A5027 after power on detected Recycle power. See operator's manual if White Module found. Module has been problem continues A5028 communication detected but is lost lost Module not detected ATCM not...

  • Page 56: General Specification - System Protection Data

    INTRODUCTION General specification - System protection data FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser In case of an emergency, in order to prevent the engine or the hydrostatic system damage, or to protect your personal...
  • Page 57 INTRODUCTION 48142788 28/04/2017...
  • Page 58 INTRODUCTION 48142788 28/04/2017...

  • Page 59: Product Identification

    INTRODUCTION Product identification FR Forage Cruiser series EXPLANATION OF MACHINE SERIAL NUMBERS Example : n° 725902002 72 5902002: The first two digits identify the model within a product line: FR450 = 51 FR480 = 71 FR500 = 52 FR550 = 72 FR600 = 53 FR650 = 73 FR780 = 74...

  • Page 60: Machine Orientation - Machine Orientation

    INTRODUCTION Machine orientation - Machine orientation FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser FR850 Forage Cruiser NOTE: Throughout this operator’s manual, references to the right-hand side and the left-hand side of the machine are determined by standing at the rear of the machine and facing the direction of travel during working operation.
  • Page 61 INTRODUCTION 48142788 28/04/2017...
  • Page 62 SERVICE MANUAL Engine FR480 Forage Cruiser Cursor 13, TIER 4B (FINAL) [715912001 - 715923100] FR550 Forage Cruiser Cursor 13, TIER 4B [725912001 - 725923100] FR650 Forage Cruiser Cursor 16, TIER 4B (FINAL) [735912001 - 735923100] FR780 Forage Cruiser Cursor 16, TIER 4B (FINAL) [745912001 - 745923100]...
  • Page 63 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.216] Fuel tanks .
  • Page 64 Engine - 10 Engine and crankcase - 001 FR480 Forage Cruiser Cursor 13, TIER 4B (FINAL) [715912001 - 715923100] FR550 Forage Cruiser Cursor 13, TIER 4B [725912001 - 725923100] FR650 Forage Cruiser Cursor 16, TIER 4B (FINAL) [735912001 - 735923100]...
  • Page 65 Contents Engine - 10 Engine and crankcase - 001 SERVICE Engine Remove (*) ................3 Install (*) .
  • Page 66 Engine - Engine and crankcase Engine - Remove FR480 Forage Cruiser FR550 Forage Cruiser FR650 Forage Cruiser FR780 Forage Cruiser DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders.
  • Page 67 Engine - Engine and crankcase 5. Remove the rear shield. • Support the rear shield (2). Ask the assistance of a second person or use a suitable lifting device. • Lift up the bottom clip from the gas strut (3), then remove the gas strut (3) from the pivot bolt.
  • Page 68 Engine - Engine and crankcase Drain Fluids 8. Drain the hydraulic oil reservoir. ZEIL15FR00090AA 9. Drain the engine coolant: • Engine coolant radiator ZEIL15FR00088AA • Engine coolant intake. Close the tap, remove the hose, drain coolant, open the tap and drain fluid. •...
  • Page 69 Engine - Engine and crankcase 11. Remove all the straps and disconnect all the connec- tors of the wiring harness branch (see arrow) going down of the wiring harness (6) and lay the wiring har- ness branch on top of the roof assembly. See the lo- cation diagram in the service manual.
  • Page 70 Engine - Engine and crankcase Roof assembly 16. Remove the hardware (10) (fourteen in total) and the cooling group cover plate (12). 17. Disconnect the hoses (11) from the engine coolant reservoir. ZEIL15FR00091AA 18. Remove the hose (14) from the engine coolant intake tube.
  • Page 71 Engine - Engine and crankcase 24. On the left-hand side of the machine, disconnect the DEF/AdBlue® feed line from the supply module. NOTE: Have a suitable container ready and use the appro- priate plugs on the DEF/AdBlue® supply module and the DEF/AdBlue®...
  • Page 72 Engine - Engine and crankcase 31. Support the roof assembly with a suitable lifting de- vice. Use the lifting eyes near the front hinges of the side shieldings, and use the spout support as shown. ZEIL15FR00116AA 32. On the left-hand side of the machine, remove the hardware (29).
  • Page 73 Engine - Engine and crankcase 35. On the right-hand side of the rear frame, remove the hardware (32). ZEIL15FR00121AA 36. On the left-hand side of the rear frame remove the hardware (32). ZEIL15FR00120AA 37. Remove the hardware (33). ZEIL15FR00119AA 38. Make sure nothing remains connected to the roof as- sembly.
  • Page 74 Engine - Engine and crankcase Air and coolant tubes 39. Loosen the clamp (34) of the cooling group air intake tube (35). ZEIL15FR00138AA 40. Loosen the clamp (37). 41. Remove the clamp hardware (36). Remove the air intake tube (35). ZEIL15FR00137AA 42.
  • Page 75 Engine - Engine and crankcase 48. Loosen the hose clamp (46) of the engine coolant out- let tube (43). 49. Remove the clamp hardware (45) and remove the en- gine coolant outlet tube (43). NOTE: The tube is full of engine coolant. ZEIL15FR00145AA 50.
  • Page 76 Engine - Engine and crankcase Cooling fan 56. On the fan support, remove the hardware (54) of the oil filter (53). Lay the oil filter (53) down without re- moving the hoses. ZEIL15FR00126AA 57. Remove the hardware (56) of the support (57). 58.
  • Page 77 Engine - Engine and crankcase 64. Support the fan (65). Use a suitable lifting device. 65. Remove the hardware (64) and remove the fan (65) from the machine. ZEIL15FR00129AA Hydraulics 66. Disconnect the connectors (7A), (7B), (7C), (7D), (7E), (7F) and (7G) of the wire harness (7). See also Figure 45.
  • Page 78 Engine - Engine and crankcase 69. Remove the hose (66), the hose (67), and the hose (68). ZEIL15FR00133AA 70. Remove the hose (77), the hose (81), the hose (78), the hose (79) and the hose (80). ZEIL15FR00132AA 71. Remove the clamp hardware (82). Disconnect the tube (83).
  • Page 79 Engine - Engine and crankcase Rear Frame 73. On the rear right-hand side of the machine. Remove the hardware (84). ZEIL15FR00154AZ 74. On the rear right-hand side of the machine. Remove the hardware (84). ZEIL15FR00155AA 75. On the rear right-hand side light cover (86). Remove the plastic rivet (85).
  • Page 80 Engine - Engine and crankcase 78. Ask assistance of a second person or use a suitable lifting device to support the rear frame (88). 79. Remove the hardware (89). ZEIL15FR00158AA 80. On the left-hand side of the rear frame (88). Remove the hardware (89) and remove the rear frame (88).
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