New Holland FR450 TIER 3 Service Manual
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New Holland FR450 TIER 3 Service Manual

Forage harvester
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SERVICE MANUAL
FR450 / FR500 / FR600 / FR700 / FR850
Forage Harvester
Part number 47812470
English
February 2015
Replaces part number 47688004

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  • Page 1 SERVICE MANUAL FR450 / FR500 / FR600 / FR700 / FR850 Forage Harvester Part number 47812470 English February 2015 Replaces part number 47688004...
  • Page 2 SERVICE MANUAL 47812470 23/02/2015 Find manuals at https://best-manuals.com...
  • Page 3 Link Product / Engine Product Market Product Engine FR850 FR850 TIER 2 [5803 - ] North America FVAE2884X*B200 FR450 FR450 TIER 3 [5803 - ] North America F2CE9684U*E151 FR500 FR500 TIER 4A North America F3BFE613E*A FR600 FR600 TIER 3 [5803 - ]...
  • Page 4 Contents INTRODUCTION Engine..................10 [10.001] Engine and crankcase ............. 10.1 [10.218] Fuel injection system .
  • Page 5 Hydrostatic drive................. 29 [29.100] Transmission and steering hydrostatic control ........29.1 [29.218] Pump and motor components.
  • Page 6 Wheels ..................44 [44.511] Front wheels............... . 44.1 [44.520] Rear wheels .
  • Page 7 [55.DTC] FAULT CODES..............55.22 Attachments/Headers..............
  • Page 8 INTRODUCTION 47812470 23/02/2015 Find manuals at https://best-manuals.com...

  • Page 9: Table Of Contents

    Contents INTRODUCTION Basic instructions - How to use and navigate through this Manual ......3 Advice .

  • Page 10: Basic Instructions - How To Use And Navigate Through This Manual

    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.
  • Page 11 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 12 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 13 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 14 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 15 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 16 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 17: Advice

    INTRODUCTION Advice All repair and maintenance works listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given; and using, whenever appropriate, the special tools. Anyone who carries out the above operations without complying with the instructions shall be responsible for the subsequent damages.

  • Page 18: Note To The Owner

    INTRODUCTION Note to the Owner FR450 FR500 FR600 FR850 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. Fault Code Resolution (FCR) information: For FCR information, please refer to the Electronic Service Tool (EST) or to the information given in the paper or electronic version of this manual.

  • Page 19: Safety Rules

    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 in- structions.

  • Page 20: 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 21: Safety Rules

    INTRODUCTION Safety rules 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. ACCIDENT PREVENTION Most accidents or injuries that occur in workshops are the result of non compliance to simple and fundamental safety principles.
  • Page 22 INTRODUCTION • Bring all hydraulic cylinders to the home positions (down, retracted, etc.) before engine shut down. • Stop the engine and check that the hydraulic circuits are pressure-free before removing caps, covers, valves, etc. • All repair and maintenance operations must be carried out using extreme care and attention. •...
  • Page 23 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 24: Personal Safety

    INTRODUCTION Personal safety WARNING Heavy object! ALWAYS use a hoist or get assistance to lift the component. Failure to comply could result in death or serious injury. W0086A WARNING Pressurized system! Only use the bleed screw to bleed air from the fuel system. DO NOT loosen the fuel or injector lines to bleed air.

  • Page 25: 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 26 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 27: Torque

    INTRODUCTION Torque 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. The minimum hardware tightening torque on drawings, in specifications etc.
  • Page 28 INTRODUCTION ZEIL06CS0136F0A ZEIL06CS0135F0A 47812470 23/02/2015...

  • Page 29: Basic Instructions - Chain Wear Tables - Roller Chains

    INTRODUCTION Basic instructions - Chain Wear Tables - Roller Chains 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. A material is worn away from these surfaces the chain will gradually elongate. ZEIL10GH0003A0B Chains do not "stretch"...
  • Page 30 INTRODUCTION For example, if 40 pitches (40 pins) of a #40 chain were measured and the result was 523 mm (20.6 in) or greater (using 3 % as the maximum allowable wear), the chain should be replaced. Anything less than 523 mm (20.6 in) would still be acceptable by most industrial standards.

  • Page 31: Conversion Factors

    INTRODUCTION Conversion factors Length 1 mm 0.0393 in 1 in 25.4 mm 1 km 0.621 miles 1 miles 1.609 km 3.281 ft 1 ft 0.3048 m Area 1 ha 2.471 ac 1 ac 0.404 US fl oz 1 m² 10.76 ft² 1 ft²...

  • Page 32: General Specification System Protection Data

    INTRODUCTION General specification System protection data In case of an emergency, in order to prevent the engine or the hydrostatic system damage, or to protect your personal safety, the engine will automatically be shut off, if the elements mentioned in the table below occur: NOTICE: If it is necessary to move the forage harvester for safety reasons, the engine can be (re-) started after an automatic engine shut off.
  • Page 33 INTRODUCTION 47812470 23/02/2015...
  • Page 34 INTRODUCTION 47812470 23/02/2015...

  • Page 35: Product Identification

    INTRODUCTION Product identification EXPLANATION OF MACHINE SERIAL NUMBERS Example : n° 615848002 615848001: The first two digits identify the model within a product line: FR450 (Tier 3 units) = 51 FR450 (Tier 4 units) = 61 FR500 (Tier 3 units) = 52 FR500 (Tier 4 units) = 62 FR600 = 53 FR700 = 54...
  • Page 36 SERVICE MANUAL Engine 47812470 23/02/2015...
  • Page 37 Contents Engine - 10 [10.001] Engine and crankcase ............. . . 10.1 [10.218] Fuel injection system .
  • Page 38 Engine - 10 Engine and crankcase - 001 47812470 23/02/2015 10.1 [10.001] / 1...
  • Page 39 Contents Engine - 10 Engine and crankcase - 001 SERVICE Engine Remove (*) ................3 Install (*) .
  • Page 40 Engine - Engine and crankcase Engine - Remove FR450 FR500 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. Failure to comply will result in death or serious injury.
  • Page 41 Engine - Engine and crankcase 5. For better access to the components, remove the steer- ing wheels. Refer to Rear wheel - Remove – Steering wheels (44.520). 6. In the service area, loosen the lock nut (13) and the nut (12) until the worm (14) is completely free of the worm wheel (15).
  • Page 42 Engine - Engine and crankcase 10. Near the coolant tank, disconnect the connectors. Disconnect the coolant level sensor wire (105) at- tached at the top. ZEIL13FR00307AB 11. Drain the coolant from the cooling system. Refer to the Operator's Manual Engine cooling system - Re- place (10.400).
  • Page 43 Engine - Engine and crankcase 17. On the right-hand side, remove the wire harness (25) attached at the top and at the rear frame. ZEIL11FR0033B0Z 18. On the left-hand side, remove the wire harness (27) attached at the top and the rear frame. ZEIL11FR0034B0Z 47812470 23/02/2015 10.1 [10.001] / 6...
  • Page 44 Engine - Engine and crankcase 19. On both sides at the rear of the engine roof assembly (104), remove the hardware (103). ZEIL13FR00308AB ZEIL13FR00309AB 20. On the left-hand side of the engine roof assembly (104), remove the hardware (103). ZEIL13FR00310AB 21.
  • Page 45 Engine - Engine and crankcase 22. From the engine roof assembly, remove the hardware (70). Remove the plate (125). ZEIL13FR00101AZ 23. On the left-hand side of the radiator fan plastic cover (102), remove the hardware (103) from the engine roof assembly (104).
  • Page 46 Engine - Engine and crankcase If "cutterhead reverse drive" is installed, perform steps 29 and 30 29. On the left-hand side, remove the hose (34) from the tube (61). 30. Remove the reverse drive belt (32). Refer to Drum gearbox Belt drive - Remove - Reverse drive belt. (64.130).
  • Page 47 Engine - Engine and crankcase 34. On the right-hand side near the water tube (37), re- move the hardware (38). Remove all the clamps. 35. Remove the intercooler tube (8) and the water tube (7). Refer to figures 22 and 23. ZEIL13FR00314AB 36.
  • Page 48 Engine - Engine and crankcase 39. On the right-hand side, loosen the clamp (41) near the turbocharger end. Disconnect and remove the tube (40). ZEIL13FR00316AB 40. In the service area, remove the cover plate (120) to have access to the batteries. ZEIL12FR0203A0Z 41.
  • Page 49 Engine - Engine and crankcase 43. On the right-hand side, disconnect the air-condition- ing hose (48) and (49) from the air-conditioning pump (50). ZEIL13FR00318AB 44. On the left-hand side, disconnect the Engine Control Unit (ECU) connector (51) from the ECU (52). Discon- nect the ECU fuel tube (56).
  • Page 50 Engine - Engine and crankcase 47. From the oil reservoir (18), disconnect the hose (62), (63) and (64). ZEIL13FR00325AB 48. On the right-hand side, disconnect the connector (115). Remove the wire harness (113). Disconnect the tube (80) from the lubrication oil cooler. ZEIL13FR00326AZ 49.
  • Page 51 Engine - Engine and crankcase 51. On the left-hand side, disconnect the tube (81) from the suction filter (118). ZEIL13FR00078AF 52. Remove the fan drive belt. Refer to Belt - Remove (10.414). 53. Swing the idler arm upwards and retain the idler arm in the upward position.
  • Page 52 Engine - Engine and crankcase 57. Behind the radiator, remove the support (68). ZEIL13FR00329AB 58. On the rear of the engine, disconnect and remove the hose (10) from the drain tap. ZEIL13FR00323AZ 59. On the right-hand side, disconnect the hose (53) from the filter assembly (54).
  • Page 53 Engine - Engine and crankcase 62. On the main gearbox assembly, disconnect the hose (69) from the gear pump (steering). Disconnect and remove the hose (63) and (62). ZEIL13FR00330AB 63. On the main gearbox, disconnect the hose (74). Dis- connect and remove the hose (75). ZEIL13FR00331AB 64.
  • Page 54 Engine - Engine and crankcase 67. On the right-hand side, disconnect the hose (85) from the tube (86). Disconnect the hose (87) from the tube (88). ZEIL13FR00334AB 68. On the main gearbox, disconnect the tube (89) from the gear pump (main gearbox lubrication) (90). Dis- connect the tube (116) from the tube (117).
  • Page 55 Engine - Engine and crankcase 71. Loosen the hardware (97) from the muffler (24). Re- move the muffler from the engine frame. Use a suit- able lifting device. ZEIL13FR00338AZ 72. At the rear, remove the tube (58) from the oil reservoir (18).
  • Page 56 Engine - Engine and crankcase 75. On the left-hand side, remove all the hardware (100). Remove the hardware (100) from the inner side also. ZEIL13FR00341AZ 76. Attach the hooks (H) of a suitable lifting device on the indicated areas of the engine and the main gearbox. ZEIL13FR00342AB 77.
  • Page 57 Engine - Engine and crankcase 79. Place the engine and the main gearbox assembly on the wooden blocks (W). ZEIL13FR00345AB 80. Remove the hardware (121) from the engine flange. Separate the main gearbox assembly from the engine. NOTICE: Main gearbox assembly is heavy. Use a suitable lifting device.
  • Page 58 Engine - Engine and crankcase Engine - Install FR450 FR500 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. Failure to comply will result in death or serious injury.
  • Page 59 Engine - Engine and crankcase NOTICE: Make sure that the tubes connected to the valves and the air intake filter are not damaged during the follow- ing procedure. 3. Attach the chain hooks (H) on the indicated areas. Lift the engine and the gearbox assembly. Use a suitable lifting device.
  • Page 60 Engine - Engine and crankcase 8. On both sides, on the rear of the machine, install the hardware (98) on the engine support. ZEIL13FR00339AB 9. At the rear of the machine, install the tube (58) on the oil reservoir (18). ZEIL11FR0048A0B 10.
  • Page 61 Engine - Engine and crankcase 12. Connect the hose (95) and (96) to the Closed Center Load Sensing (CCLS) pump on the main gearbox. NOTE: The view shown is from the top side of the main gearbox. ZEIL13FR00337AZ 13. On the left-hand side, connect the hose (91), (92) and (93) to the filter (94).
  • Page 62 Engine - Engine and crankcase 16. On the right-hand side, install the hose (64), (111) and (112) as shown. 17. Install the supports (109) and (110). ZEIL13FR00333AB 18. On the right-hand side, connect the hose (77) to the fitting (76). ZEIL13FR00332AB 19.
  • Page 63 Engine - Engine and crankcase 21. On the rear of the machine, install the filter assembly (54). Use the bolts (107). 22. Install the hose (55) to the filter (54). ZEIL13FR00322AB 23. On the right-hand side, connect the hose (53) to the filter assembly (54).
  • Page 64 Engine - Engine and crankcase 26. Connect the hook of a suitable lifting device to the pulley (67) of the radiator fan assembly. 27. Carefully lift and position the radiator fan assembly (65) to the machine. ZEIL13FR00328AB 28. Install the radiator fan assembly (65) on the machine. On both sides, use the hardware (66).
  • Page 65 Engine - Engine and crankcase 32. On top of the main gearbox, connect the main gearbox lubrication valve hose (78) and (79) to the tube (80) and (81). ZEIL11FR0061A0B 33. On the right-hand side, install the hose (82) and (83) on the oil filter (84).
  • Page 66 Engine - Engine and crankcase 36. On the right-hand side, connect the connector (17) and other connectors to the feed rolls hydrostatic pump (in case of single drive). NOTE: If installed, do the same for the attachment hydro- static pump (in case of double drive). ZEIL13FR00324AZ 37.
  • Page 67 Engine - Engine and crankcase 40. On the left-hand side, connect the connectors (71) and (72) to the alternator (73). ZEIL11FR0058A0B 41. In the service area, connect all the terminals (42) to the batteries. ZEIL13FR00317AB 42. Install the cover plate (120). ZEIL12FR0203A0Z 43.
  • Page 68 Engine - Engine and crankcase 44. On the left-hand side, connect the other end of the tube (40) to the muffler (24). ZEIL13FR00315AZ 45. On the left-hand side, install the intercooler tube (44). ZEIL11FR0049A0Z 46. On the left-hand side, install the water tube (59) on the hose (60).
  • Page 69 Engine - Engine and crankcase 48. On the right-hand side, install the intercooler tube (8). Use the clamps (9) and the other clamp (not indi- cated). ZEIL13FR00096AA 49. On the left-hand side, install the air intake duct (35) and (36). ZEIL11FR0038A0B If "cutterhead reverse drive"...
  • Page 70 Engine - Engine and crankcase 54. On both sides of the engine roof assembly (104), in- stall the eye bolt (E). 55. Attach the chain (C) of a suitable lifting device to the eyebolts and the engine roof assembly (104). 56.
  • Page 71 Engine - Engine and crankcase 60. On the left-hand side of the engine roof assembly (104), install the hardware (103). ZEIL13FR00310AB 61. On both sides of the rear of the engine roof assembly (104), install the hardware (103). ZEIL13FR00308AB ZEIL13FR00309AB 47812470 23/02/2015 10.1 [10.001] / 34...
  • Page 72 Engine - Engine and crankcase 62. On the left-hand side, route the wiring harness (27) as shown at the top and the rear frame. ZEIL11FR0034B0Z 63. On the right-hand side, route the wiring harness (25) as shown at the top and the rear frame. ZEIL11FR0033B0Z 47812470 23/02/2015 10.1 [10.001] / 35...
  • Page 73 Engine - Engine and crankcase 64. On the left-hand side, install the sensor bracket (2). Use the hardware (1). ZEIL13FR00305AB 65. Install the exhaust tube (23) on the muffler (24). 66. Install the clamp (30). Use the hardware (29). ZEIL13FR00306AZ 67.
  • Page 74 Engine - Engine and crankcase 73. Refill the earlier drained hydraulic oil into the hydraulic oil reservoir (18). Top up as necessary. Refer to the Operator's Manual Oil filter - Replace (29.204). NOTE: On the right-hand side under the machine, ensure the indicated drain plug on the fuel tank is fully tightened.
  • Page 75 Engine - Engine and crankcase 82. On both sides, install the indicated plate. ZEIL12FR0204A0Z 83. Install the left-hand and right-hand side shielding. Re- fer to Side shields - Install side shieldings (90.105). 84. Bleed the fuel system. Refer to the Operator's Man- ual.
  • Page 76 Index Engine - 10 Engine and crankcase - 001 Engine - Install (*) ................. 21 Engine - Remove (*) .
  • Page 77 47812470 23/02/2015 10.1 [10.001] / 40...
  • Page 78 Engine - 10 Fuel injection system - 218 47812470 23/02/2015 10.2 [10.218] / 1...
  • Page 79 Contents Engine - 10 Fuel injection system - 218 FUNCTIONAL DATA Fuel injection system Overview ................. . 4 47812470 23/02/2015 10.2 [10.218] / 2...
  • Page 80 47812470 23/02/2015 10.2 [10.218] / 3...
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This manual is also suitable for:

Fr500 tier 3Fr600 tier 3Fr700 tier 4aFr850 tier 2

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