New Holland FX30 FX40 FX50 FX60 Repair Manual manuals in PDF

Repair Manual For New Holland FX30, FX40, FX50, FX60 Forage Harvester. Illustrations, instructions, diagrams for step by step remove and install, assembly and disassembly, service, inspection, repair, troubleshooting, tune-up.

Format: PDF
Language: English
Pages: 1096
Bookmarks: Yes
Searchable: Yes
Number: 87342127
Wiring Diagrams: Yes
Hydraulic Diagrams: Yes

Model

New Holland FX30, FX40, FX50, FX60

Contents

• – General Information
  Introduction
  Important Information
  –General Instructions
  Shimming
  Rotating Shaft Seals
  –Ring Seals
  Sealing Compounds
  Bearings
  Cotter Pins
  Protecting The Electronic / Electrical Systems During Charging Or Welding
  –Spare Parts
  Tools
  Safety Regulations
  Accident Prevention
  — Safety Rules
  General Guidelines
  Start-Up
  Engine
  Electrical System
  Hydraulic Systems
  Wheels And Tyres
  Removal And Re-Fitting
  –
  Explanation Of Machine Serial Number
  Conversion Chart
  Hardware Tightening Torques
  Drive Line And Components
  Lubricants To Be Used
• – Engine
  — Iveco Engine F3A – General
  —Walk Around The Engine
  Left Side View
  Right Side View
  Front View
  Rear View
  Top View
  –
  The Iveco Engine
  Engine Block And Cylinder Liners
  Crankshaft
  Crankshaft Sealing Rings
  Connecting Rods
  Pistons
  Camshaft
  Timing System
  Flywheel
  Auxiliary Drivebelt
  Lubrication
  — Oil Filter
  External Coil
  Upstream Mount
  Filter Septum
  Downstream Mount
  Structural Parts
  –
  Oil Sump
  Cooling
  —Electronically Controlled Injection System
  Electronic Control Unit
  —Pump Injector
  Filling Stage
  Injection Stage
  Flow-Back Stage
  — Iveco Engine — F3A
  General Specifications
  Fuel System Data
  Main Data
  Torque Settings
  —Plan Of Tightening Sequence
  Sub–Cranckcase
  Cylinder Head
  Exhaust Manifold
  Turbocharger
  Heat Exchanger
  Engine Oil Sump
  Rocker Arm Cover
  –
  Tools
  — Mechanical Troubleshooting
  Preliminary Conditions
  Engine – DisassemblyAssembly
  General Notes
  Cranckshaft
  Pistons, Pistons Rings And Connecting Rods
  Cylinder Head
  Oil Pump And , Timing System Intermediate Gears
  Engine Flywheel
  Camshaft
  Injectors Pump
  Rocker Arm Shaft
  Completing The Engine
  Assembly Diagram For Fan Drive Belt – Water Pump – Alternator
  Cranckcase, Cylinder Liners
  Cranckshaft, Bearings
  —Selecting Main And Big End Bearing Shells
  Main Journals
  Crankpins
  Selecting Small End Bearings (Pins With Nominal Diameter)
  Selecting The Main Bearing Shells (Pins With Nominal Diameter)
  Selecting The Main Bearing Shells (Pins With Nominal Diameter)
  Selecting The Main Bearing Shells (Ground Pins)
  Selecting The Big End Bearing Shells (Pins With Nominal Diameter)
  Selecting The Big End Bearing Shells (Ground Pins)
  Checking Main Journal Assembly Clearance
  Tightening Sequence Of The Screws Fixing The Sub–Crankcase Under The Crankcase
  Remove The Sub–Crankcase
  Checking Crankshaft End Float
  –
  Pistons
  Connecting Rods
  Piston And Connecting Rod – Assembly
  Cylinder Head
  Tappets And Camshaft
  Valve Springs, Rocker Arm Shaft And Rocker Arms
  Lubrication System
  Cooling Circuit
  Fuel Supply
  Replacing The Valve Guides
  Injector Case – Replacement
  Cranckshaft Front Cover Seal – Replacement
  Adjusting Clearance Of Rocker Arms To Valves And Pre–Load Of Pump Injector Rocker Arms
  Pump Injector – Removal — Refitting
  Bleeding The Fuel Supply System
  Water Pump – Removal-Refitting
  Thermostat – Removel – Refitting
  –Iveco Engine F3B – General
  Engine Description
  Engine Main Components
  Cranckshaft
  Crankcase Gas Ring
  Connecting Rods
  Pistons
  Cylinder Head
  Camshaft
  Intake Valve Control
  Exhaust Valve Control
  Injector–Pump Control
  Camshaft Drive
  Camshaft Driving
  Engine Flywheel
  Auxiliary Component Control
  Oil Sump
  Oil Filter
  Fuel Supply
  —Main Components Of The Ms62 Edc System
  Pump Injector
  —-Operation
  Filling Phase
  Injection Phase
  Pressure Reduction Phase
  Ms62 Electronic Control Unit13
  —Control Unit Operation14
  Fuel Batching14
  Flow-Rate Correction Depending On Water Temperature
  Flow-Rate Correction To Avoid Noises, Fumes Or Overloads
  De-Rating
  Electronic Injection Spark Advance Check
  Speed Regulator
  Engine Start–Up
  Cold Start–Up
  Hot Start–Up
  Run Up
  After Run
  Cylinder Balancing
  Synchronisation Search
  –
  Engine Coolant Temperature Sensor
  Fuel Temperature Sensor
  Supercharging Air Temperature Sensor
  Supercharging Pressure Sensor
  Flywheel Sensor
  Distribution Sensor
  Pre – After Heating Resistance
  — Iveco Engine F3B
  General Specification
  Fuel System Data
  Main Data
  Torque Settings
  Plan Of Tightening Sequence
  Tools
  Mechanical Troubleshooting
  Engine – Disassembly Assembly
  General Notes
  Crankshaft
  Pistons And Connecting Rods
  Cylinder Head
  Oil Pump And Intermediate Timing Gears
  Engine Flywheel
  Camshaft
  Injectors Pump
  Rocker Arm Shaft
  Completing The Engine
  Crankcase And Cylinder Liners
  Crankshaft And Bearings
  Selecting Main And Big End Bearing Shells
  — Preliminary Appraisal Of Data To Make The Selection
  Main Journals
  Crankpins
  Selecting Small End Bearings (Pins With Nominal Diameter)
  Selecting The Main Bearing Shells (Pins With Nominal Diameter)
  Selecting The Main Bearing Shells (Pins With Nominal Diameter)
  Selection Of Main Half-Bearings (Rectified Pins)
  Selecting The Big End Bearing Shells (Pins With Nominal Diameter)
  Selection Of Connecting Rod Half-Bearings (Rectified Pins)
  Checking Main Journal Assembly Clearance
  Remove The Sub–Crankcase
  Checking Crankshaft End Float
  –
  Pistons
  Connecting Rods
  Piston – Connecting Rod Assembly
  Cylinder Head
  Valves
  Tappets And Camshaft
  Valve Springs, Rocker Arm Shaft And Rocker Arms
  Lubrication System
  Cooling System
  Fuel Supply
  Valve Guides – Replacement
  Injector Case – Replacement
  Crankshaft Front Cover Seal – Replacement
  Clearance Of Valves To Rocker Arms And Pre-Load Of Pump Injector Rocker Arms
  Pump Injector – Removal, Refitting
  Bleeding The Fuel Supply System
  Water Pump – Removal, Refitting
  Thermostat – Removal, Refitting
  — Caterpillar Engine
  General
  New Holland – Caterpillar
  Caterpillar Engine
  Service / Parts
• – Live P.T.O.
  — Main Drive Belt Assembly
  Tightening Torques And Adjustments
  Main Drive Belt Assembly – Remove
  Tensioner Pulley Assembly
  Cutterhead Drive Pulley
  Main Drive Pulley
  —Cutterhead Drive Pulley Carrier
  Cutterhead Reverse Drive Motor Coupling
  Cutterhead Drive Pulley Shaft
  –
  Main Drive Belt Assembly – Install
  Tightening Torques And Adjustments
  Special Tools
  —Main Drive Gearbox – Remove
  Battery Box – Remove
  Fuel Reservoir – Remove
  –
  Rubber Vibration Damper – Replace
  —Main Drive Gearbox – Disassemble / Assemble
  Splitting The Main Drive Gearbox
  —-Lower Gearbox Half – Disassembly / Assembly
  Disassembly
  Assembly
  Intermediate Gear Assembly
  Hydro Gear Assembly
  —-Upper Gearbox Half – Disassembly / Assembly
  Main Hydraulic Clutch – Remove
  Output Shaft – Remove / Install
  Main Clutch – Install
  Connecting The Two Gearbox Halves Together
  —Main Clutch – Overhaul
  Pressure Hose – Remove / Install
  Clutch Plates – Replace
  Clutch Seals – Replace
  — Main Drive Gearbox Series 5298 > ….
  Special Tools
  Main Drive Gearbox – Shafts
  General
  Main Drive Shaft – Remove
  Main Clutch – Remove
  Main Clutch – Disassemble
  Main Clutch – Assemble / Install
  Main Drive Shaft – Disassemble
  Main Drive Shaft – Assemble
  Main Drive Shaft – Install
  Main Drive Gearbox – Remove / Install
  —Main Drive Gearbox – Disassemble / Assemble
  Splitting The Main Drive Gearbox
  —-Lower Gearbox Half – Disassemble / Assemble
  Disassemble
  Assemble
  –
  Main Drive Gearbox – Assemble
• – Transmission
  Specifications
  Tightening Torques And Adjustments
  Special Tools
  Gearbox Shafts
  Shifting Diagram
  —Disassembly Of Traction Gearbox
  General
  Removal Of Selector Forks And Shifter Shafts
  Removal Of Drive Shaft
  Removal Of The Countershaft
  Removal Of Transmission Main Shaft
  Removal Of The Half–Shaft From The Differential
  Removal Of The Differential
  —Assembly Of Traction Gearbox
  Assembly Of The Differential
  Assembly Of The Half–Shafts Of The Differential
  Assembly Of Transmission Main Shaft
  Assembly Of The Countershaft
  Assembly Of The Drive Shaft
  Assembly Of Selector Shafts And Forks
  Calculation Of Shims To Be Installed On The Shafts
  Assembly Of The Cover
  Specifications
  Tightening Torques
  —Special Tools
  Self-Made Tools
  –
  Gearbox Shafts
  Wd Gearbox – Removal
  Wd Gearbox – Components
  —Wd Gearbox – Disassembly
  Intermediate Shaft
  Input Shaft
  Output Shaft And Clutch
  Clutch Cylinder
  —Wd Gearbox – Assembly
  Clutch Cylinder
  Output Shaft And Clutch – Pre Assembly
  Input Shaft – Pre Assembly
  Intermediate Shaft – Installation
  Input Shaft – Installation
  Cover – Installation
  Clutch Pre-Assembly – Installation
  –
  Wd Gearbox – Installation
• – Front Mechanical Drive
  — Final Drives Fx30
  —Final drives – Disassembly
  Output shaft
  Input shaft
  —Final drives – Assembly
  Input shaft
  End play adjustment
  Output shaft
  Preload adjustment
  — Final Drives Fx40-50-60
  Specifications
  Tightening Torques
  Gearbox Shafts
  Wheel Bolt – Replacement
  Final Drive – R/ I
  —Final Drive D/A
  Disassembly
  Assembly
  – Hydrostatic System
  —Hydrostatic Circuit And Components
  Circuit
  –
  Hydrostatic Pump And Motor Identification Plate
  —Hydrostatic Pump
  Pump Operation
  Circuit
  Pump Characteristics
  Multifunction Valve
  —-Servo Valve
  System In Neutral
  Servo Solenoid Valve Energized
  —Hydrostatic Motor
  Fixed Displacement Motors
  Drive Motor Characteristics
  –
  Oil Cooler Bypass Valve
  Filling And Bleeding The Hydrostatic System
  Starting The Hydrostatic System
• – Brakes And Control
  —Brake System
  General
  Road Mode
  –
  Parking Brake Adjustment
  —Replacement Of The Brake Linings
  Removal
  Installation
  —Bleeding The Brakes
  Bleeding The Left-Hand Side Circuit
  Bleeding The Connection Pipe Between The Two Main Cylinders
  Bleeding The Right-Hand Side Circuit
  —Disassembly And Assembly Of Brake Shoes And Discs
  Disassembly Of Brake Shoes
  Disassembly Of Brake Discs
  Assembly Of Brake Discs
  Assembly Of Brake Shoes
• – Hydraulic System
  — General
  —Torque Tables For Hydraulic Components
  Union Nuts
  Ferrules
  —-Metric Fittings
  Unions
  Connections
  Swivel Nut With Ball-Type Nipple
  –
  Pump Group – Disassembly And Assembly
  —Disassembly Of The Pump Group
  Removal Of The Triple Pump From The Hydrostatic Pump
  Splitting Of The Triple Pump
  Assembly Of The Pump Group
  Installation Of The Pump Group To The Hydrostatic Pump
  — Work Hydraulics – Attachment Height Control
  —Circuit Diagrams
  Work Hydraulics – Attachment Height Control
  –
  Hydraulic Oil Reservoir
  Low Pressure Filter
  Breather
  High Pressure Filter
  —Non-Return Valve
  Function
  —Work Hydraulics Pump
  Specifications
  –
  High Pressure Relief Valve
  —Attachment Height Control Valve (Emr)
  Neutral Position
  Attachment Lifting Position
  Attachment Lowering Position
  Pressure Relief Valve H
  Emergency Hand Buttons
  Specifications
  —Attachment Compensation Valve
  Specifications
  Transport Mode
  Compensation Mode
  Stubble Height Mode
  —Pressure Sensor
  Specifications
  —Hydropneumatic Accumulators
  Filling
  Attachment Lift Cylinders
  — Work Hydraulics – Base Unit
  Circuit Diagrams – Base Unit
  —Stack Valve
  Repair Of Control Valves
  —Load Sensing Valve
  System In Neutral
  —Cutterhead Reverse Drive Motor
  Specifications
  –
  Spout Rotation Pressure Relief Valve
  —Spout Rotation Motor
  Specifications
  —Quick-Release Couplings
  Specifications
  —Spout Lift Cylinder
  Cylinder Disassembly And Assembly
  Reinstallation Of Spout Lift Cylinder
  — Steering Hydraulics
  Circuit Diagrams — Steering Hydraulics
  —Steering Hydraulics Pump
  Specifications
  —Steering Valve
  Special Tools
  Steering Valve – D/A
  —Steering Cylinders
  Disassembly And Assembly
  Toe-In Adjustment, Steering Ball Joints, Steering Wheel Stops
  — Low Pressure Hydraulics
  Circuit Diagrams – Low Pressure Hydraulics
  —Low Pressure Hydraulic Reservoir
  Oil And Filter Change Procedure
  Oil Pressure Check Procedure
  Filling The System When (Re)Installing The Low Pressure Pump
  Filling The System After (Re)Installing The Main Drive Transfer Gearbox
  —Low Pressure Pump
  Specifications
  –
  Low Pressure Valve
  Main Drive Belt Tensioning Cylinder
  Spout Deflector Cylinder
  — High–Flow Hydraulics
  Circuit diagrams – High-Flow hydraulics
  – Cab Climate Control
  Correct Use Of The Airconditioning System
  Storage Maintenance
  —Air Conditioning Circuit
  Components
  —Specifications
  Refrigerant
  Compressor
  Compressor Clutch
  Circuit Parameters
  Low Pressure Switch
  High Pressure Switch
  Filter-Drier
  —Compressor Clutch Replacement
  Clutch Removal
  Clutch Installation
  –
  Ventilation Unit
• – Electrical System
  — General
  —General information
  Wires
  Color code
  Wire identification
  Fuses
  Symbols
  Relays
  –
  Connectors
  — Wiring Diagrams Fx North America
  Wiring Diagrams Fx Na
  — Can Network Basics
  Can Network Basics
  —General Layout Electronic System
  Electronic Components
  Conclusion
  —Electronic System Layout
  Input
  Output
  Analog Signals (From Input Or To Output)
  Digital Information
  Interfaces
  Software
  Calibrations
  Additional Info:
  —Can Spy
  Decimal And Hexadecimal Counting
  Decimal
  Hexadecimal
  How To Use The Can Identifiers
  How To Enter Can–Spy
  Can–Spy In Practice
  —Error Codes Messages
  Wiring Checking Procedure
  –
  Fault Finding Routine
  — Calibration
  General
  Special tools
  —Machine calibration with EST tool
  Configuration Item Selection screen
  Maximum Handle position calibration
  Minimum forward pump current calibration
  Minimum reverse pump current calibration
  Vehicle Configuration
  — Software Update
  Software Revision
  Software Update With Est Tool
  — Troubleshooting
  Machine Error Messages
  —Attachment Height Control Error Messages
  Error Reports
  –
  Caterpillar Error Messages
  Cursor Error Messages
  List Of Can Identifiers
  Detailed Analisys Per Function
  Electric Conditions, Engine Running Or Not Running
  Engine Protection
  Harvest Mode
  Engine Acceleration
  Cutterhead Engagement
  Feed Rolls Forward Engagement
  Feed Rolls Reverse Engagement
  Power Reverse
  Four-Wheel Drive
  Spout Rotation
  Raise / Lower Spout
  Spout Deflector
  Reverse Cutterhead
  Auxiliary Front Hydraulics
  Auxiliary Rear Hydraulics
  Air Conditioning
  Silage Additives Application
  Knife Sharpening
  Adjust-O-Matic Routine
  Crop Processor
  Metal Detector Operation And Troubleshooting
  Attachment Height Control
  Ground Speed
  High Flow Hydraulics
  Rotary Screens
  Rotary Screen Brushes
  Caterpillar Engine
  Can Network
  Auto Pilot
  Automatic Greasing
  Cursor Engine Fx30-40-50
  Feedroll Speed
  – Product Feeding
  — Feed Rolls
  —Metal Detector Roll
  Removal
  Disassembly
  —-Metal Detector Components – D/A
  Disassembly
  Assembly
  Assembly
  Installation
  —Smooth Roll
  Removal
  Installation
  —Upper Feed Rolls – R/I
  Before Removal
  Removal Of The Upper Feed Rolls As A Complete Assembly
  Removal Of The Upper Feed Rolls As Separate Components
  Replacing Wear Plates On The Upper Feed Rolls Frame
  Installation
  — Hydroloc Gearbox
  —Hydroloc gearbox – R/I
  Removal
  Installation
  –
  Gearbox shafts
  Specifications
  —Hydroloc gearbox — D/A
  Alternative drive shaft
  Transfer shaft
  Upper feed rolls drive shaft
  Selector shaft
  Smooth roll drive shaft
  Metal detector roll drive shaft
  Reinstall the alternative drive shaft
  Install seals and covers
  — Attachments Drive Gearbox
  —Attachments Drive Gearbox – R/I
  Removal
  Installation
  –
  Gearbox Shafts
  Specifications
  —Attachments Drive Gearbox – D/A
  —-Assembly
  Idler Shaft
  Input Shaft
  Transfer Shaft
  Attachment Drive Shaft
  Idler Shaft – Re-Installation
  — Upper Feed Rolls Drive Gearbox
  Special Tools
  —Upper Feed Rolls Drive Gearbox – R/I
  Removal
  Installation
  –
  Gearbox Shafts
  Specifications
  —Upper Feed Rolls Drive Gearbox – D/A
  —-Assembly
  Upper Feed Rolls Drive Shaft
  Front Upper Feed Roll Drive Shaft f
  Rear Upper Feed Roll Drive Shaft
  Re-Install The Upper Feed Rolls Drive Shaft
  Seals And Cover
• – Chopping
  — Cutterhead
  Splitting Of Components
  —Rotor And Bearings – R/I
  Removal
  Assembly
  –
  Shearbar – R/I
  —Shearbar Support – R/I
  Removal
  Installation
  — Cutterhead Gearbox
  —Cutterhead Gearbox – R/I
  Removal
  Installation
  —Cutterhead Gearbox – D/A
  Oil Cooler – D/A
  —-Gearbox – Disassembly
  Input Shaft
  Output Shaft
  —-Gearbox – Assembly
  Input Shaft
  Output Shaft
  Backlash
  – Ejection
  — Blower Gearbox
  Inspection Between Cutterhead And Blower
  Blower – R/I
  Blower Gearbox – R/I
  —Blower Gearbox – D/A
  Disassembly
  Assembly
  Input Shaft
  Output Shaft
  Adjusting The ShimmingWhat you get

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