New Holland H8040 Self Propelled Windrowers Service Repair Manual

Page 1

H8040REPAIRMANUAL COMPLETECONTENTS

SECTION00-GENERALINFORMATION2 ..............................

SECTION10-ENGINE3 ..............................................

SECTION25-FRONTMECHANICALDRIVE5 ...........................

SECTION29-HYDROSTATICTRANSMISSION6 ........................

SECTION33-BRAKESANDCONTROLS10 .............................

SECTION35-HYDRAULICSYSTEMS11 ................................

SECTION44-REARAXLE16 ...........................................

SECTION50-CLIMATECONTROL18 ...................................

SECTION55-ELECTRICALSYSTEMS22 ...............................

SECTION58-HEADERATTACHMENTS39 ..............................

SECTION88-OPTIONALEQUIPMENT42 ...............................

SECTION90-PLATFORM,CABANDDECALS43 ........................

Thefollowingpagesarethecollationofthecontentspagesfromeachsectionand chapteroftheH8040Repairmanual.CompleteRepairpart#87742969.

ThesectionsusedthroughoutallNewHollandproductRepairmanualsmaynotbe usedforeachproduct.EachRepairmanualwillbemadeupofoneorseveralbooks. EachbookwillbelabeledastowhichsectionsareintheoverallRepairmanualand whichsectionsareineachbook.

ThesectionslistedabovearethesectionsutilizedfortheH8040Self-Propelled Windrowers.

87742976 11/07 1stPrinting © 2007CNHAmericaLLC PrintedInU.S.A.
2 SECTION00-GENERALINFORMATION BOOK1-87742970 Chapter1-GeneralInformation CONTENTS SectionDescription Page 00000PrecautionaryStatements2 Safety 3 ........................................................................ GeneralSafetyInformation5 ProtectingtheElectronic/ElectricalSystemsDuringChargingorWelding7 ........... Introduction 8 AboutImprovements8 ........................................................ ProductIdentificationNumbers(PIN)9 EnginePINNumber9 ......................................................... CompanyPolicy 10 PartsandAccessories10 Lubrication 10 MinimumHardwareTighteningTorques11 InstallationofAdjustableFittingsinStraightThreadO-ringBosses13 StandardTorqueDataforHydraulicTubesandFittings13 PipeThreadFittingTorque14 ................................................. InstallationofORFS(O-ringFlatFaced)Fittings14 Specifications 15 ................................................................
3 SECTION10-ENGINE BOOK1-87742970 Chapter1-Engine CONTENTS SectionDescription Page DescriptionofOperation2 ........................................................ Specifications 2 Overhaul 3 Engine 3 Removal 3 Installation9 .............................................................. Troubleshooting 15 .............................................................. SECTION10-ENGINE BOOK1-87742970 Chapter2-FuelSystem CONTENTS SectionDescription Page FuelSystem 2 InjectionSystemBleeding2 FuelTanks 3 Removal 3 Install 7 ..................................................................
4 SECTION10-ENGINE BOOK1-87742970 Chapter3-AirIntake CONTENTS SectionDescription Page DescriptionofOperation2 AirIntakeSystem2 ........................................................... Specifications 3 AirCleaner 3 ................................................................ DescriptionofOperation4 AirFilter 4 ................................................................... Inspection4 Removal 5 ............................................................... Installation6 Troubleshooting 8 SECTION10-ENGINE BOOK1-87742970 Chapter4-CoolingSystem CONTENTS SectionDescription Page Specifications 2 .................................................................. CoolingSystem2 Overview-CoolingSystem3 ...................................................... DescriptionofOperation5 Radiator 6 ................................................................... Removal 6 Installation8 .............................................................. Troubleshooting 11
5 SECTION25-FRONTMECHANICALDRIVE BOOK1-87742970 Chapter1-FrontMechanicalDrive CONTENTS SectionDescription Page DescriptionofOperation2 SpecialTools 2 .................................................................. Overhaul 6 FrontMechanicalDrive6 ...................................................... Removal 6 Installation9 .............................................................. PlanetaryGearboxDrive12 Disassembly13 .......................................................... Assembly17
6 SECTION29--HYDROSTATICTRANSMISSION BOOK1-87742970 Chapter1--GroundDrive CONTENTS SectionDescription Page Specifications 4 .................................................................. HydrostaticTransmissionIdentification5 TorqueSpecifications6 TorqueChart 6 MotorArea 6 DescriptionOfOperation7 ........................................................ Pumps 8 .................................................................... High-pressureReliefValves9 CheckValves 9 ChargePump10 ChargeReliefValve(Pump)10 HeaderLiftPump10 ......................................................... Motors 10 VariableDisplacementMotor10 Reservoir 12 OilFlow 12 Neutral 12 ............................................................... Forward/Reverse12 ...................................................... H8040HydraulicSystemDiagram13 ........................................... H8040HydraulicSystemDiagram--DealerInstalledDraperKit15 SolenoidValve(2-speedDriveMotorOnly)17 Low-rangeOperation17 High-rangeOperation17 .................................................. CoolingCircuit17 ............................................................ ReliefValve 17 .............................................................. Operation17 Linkage 18 Operation18 Sauer-danfossAuthorizedServiceCenters--NorthAmerica19 ....................... Troubleshooting 23 .............................................................. ExcessiveNoise23
7
BOOK1-87742970
CONTENTS
Page OverheatingTransmissions23 ................................................ LossOfPropulsion23 ControlLinkageInspection24 High-pressureReliefValveCheck24 ChargePumpReliefValve25 CheckValve 25 ............................................................. PressureTesting26 .......................................................... PortLocations28 ChargePressure29 ChargePressureSystemTest30 TandemPumpChargePressureTest30 CompleteChargeSystemTest32 .......................................... HighPressureReliefValveTest34 GagePortandReliefValveLocations34 PressurePortLocations36 CasePressureTest(Pump)37 CasePressureTest(Motor)37 ............................................. SuctionTest38 .......................................................... CaseFlowTest38 ....................................................... GroundSpeedCircuit39 Operation39 Troubleshooting39 GroundSpeedDisplayDoesNotFunction40 ................................ TroubleshootingCharts42 ....................................................... WindrowerWillNotShiftIntoHighRange42 ................................. WindrowerWillNotShiftIntoLowRange43 ChargePump44 HydrostaticSystem45 ExplanationOfTermsUsedInFailureAnalysis48 ................................ LackOfLubrication48 .................................................... OperatingAtExcessiveTemperatureLevels48 Cavitation48 OverspeedingOftheUnit48
SECTION29--HYDROSTATICTRANSMISSION
Chapter1--GroundDrive(Continued)
SectionDescription
8
BOOK1-87742970 Chapter1--GroundDrive(Continued) CONTENTS SectionDescription Page PartsWornOrScoredFromContamination48 AbrasiveContaminants48 ................................................. PlatesScoredFromWaterInOil(Non-particleContaminants)48 MinorRepairs 49 ............................................................... TandemPump50 PortLocations50 ........................................................ BottomView50 RearHalfPumpBreakdown51 ............................................. FrontHalfPumpBreakdown53 ShaftSealReplacement55 SealInstaller56 ChargePumpRemoval56 ChargePumpInspection57 ChargePumpAssembly58 ORingSeals59 ......................................................... TrunnionSeal(ControlShaftSide)60 TrunnionCover(Plain)62 ................................................. TandemPumpRemoval63 TandemPumpInstallation66 .............................................. GroundDriveMotor68 Removal68 ............................................................. Inspection/PartsBreakdown69 Installation71 ............................................................ Start-up 72 Maintenance72 ............................................................. WormShaft 73 Removal73 ............................................................. Installation74
SECTION29--HYDROSTATICTRANSMISSION
9 SECTION29-HYDROSTATICTRANSMISSION BOOK1-87742970 Chapter2-PropulsionSystem CONTENTS SectionDescription Page TheoryofOperation2 PintleArmPositionSensor(B-02)3 ............................................. Removal 3 Installation3 .............................................................. Testing 4 Adjustment5 ............................................................. PropulsionRotaryPositionSensor(R-23)6 Removal 6 ............................................................... Installation6 Testing 7 MFHRotaryPositionSensor(R-18)8 Removal 8 Installation9 Testing 10 NeutralAdjustment11 ......................................................... SECTION29--HYDROSTATICTRANSMISSION BOOK1-87742970 Chapter3-ActiveCalibrations CONTENTS SectionDescription Page ActiveCalibrations2
10 SECTION29-HYDROSTATICTRANSMISSION BOOK1-87742970 Chapter4-MFHCalibration CONTENTS SectionDescription Page DealerSetupMenuNavigation2 MFHCalibration2 ............................................................ SECTION33-BRAKESANDCONTROLS BOOK1-87742970 Chapter1-BrakesandControls CONTENTS SectionDescription Page DescriptionofOperation2 SpecialTools 2 .................................................................. Overhaul 2 BrakeAssembly2 Removal 2 Installation5 Disassembly6 Rotating,Stationary,andPrimaryDiscAssembly12 Installation12 BrakeBleedingProcedure16

SectionDescription

11
BOOK2-87742971
CONTENTS
SECTION35-HYDRAULICSYSTEMS
Chapter1-HydraulicSystems
Page
5
HydraulicSystemDiagram15 HydraulicSystemOperation17 GroundDrive17
CircuitDiagrams18 HeaderDrive23 CircuitDiagrams24 ...................................................... TheoryofOperation28 ....................................................... HeaderLift28 CircuitDiagrams29 HeaderTilt 34 ............................................................... CircuitDiagrams34
ControlValveManifold38 ServiceParts38
Right-hand(RH)View40 PlanView41 ............................................................ FrontView42 RearView43 BottomView44 BackView(HiddenAgainstMountingPlate)45 ............................... SolenoidEngagementChart46
ServiceParts47
Auxiliarycontrolmanifold49 ComponentIdentificationandLocation49 Right-Hand(RH)View49
TopView50 BackView(HiddenAgainstMountingPlate)51
Introduction
SystemComponentLocations6 HydraulicManifoldsWithFactoryDraper9 ....................................... ReadingDiagramSymbols10
.............................................................
AuxiliaryEnginemountedHydraulicPump(Optional)37
......................................................... ValveIdentificationCodes39 ComponentIdentificationandLocation40
AuxiliaryControlValve(SpeedControl)Manifold47
......................................................... ValveIdentificationCodes48 ..............................................
.................................................

SECTION35-HYDRAULICSYSTEMS

Chapter1-HydraulicSystems(Continued)

CONTENTS

SectionDescription Page

HeaderControlValveManifold52

ServiceParts52 .........................................................

ValveIdentificationCodes53

HeaderDriveWithReverser54 ................................................

ComponentIdentificationandLocation54

Right-hand(RH)View54 .................................................. FrontView55

TopView56 .............................................................

CartridgeValves(Solenoid-operated)57

MainControlManifoldValves58

Two-wayTwo-position(NormallyClosed)PoppetValves58

Three-wayTwo-positionSpoolValve60

Two-wayTwo-position(NormallyOpen)PoppetValve61 (NormallyOpen)PressureReducing/RelievingValves62 (NormallyOpen)Solenoid-operatedReliefValves63 .......................... (NormallyClosed)Solenoid-operatedProportionalFlowControl63

Replacement64 .........................................................

MainManifoldñCartridgeTorqueRequirements65

Installation66 ............................................................

SolenoidCoils67

Removal67 .............................................................

Installation67

CartridgeValves(Non-solenoid-operated)68 ....................................

Direct-actingFlowControlNeedleValve68

Pilot-operatedReliefValve69 .............................................. Differential-Pressure-SensingValve70

HeaderControlManifoldñCartridgeTorqueRequirements71 ..................... NeedleValve(AD)andPilotedReliefValves72

Replacement72

Adjustment72

12
BOOK2-87742971
13
BOOK2-87742971 Chapter1-HydraulicSystems(Continued) CONTENTS SectionDescription Page MinorRepairs 73 Accumulators73 ............................................................ HeaderLift73 Removal73 ............................................................. Inspection74 Installation74 ............................................................ SurgeSuppression76 Specifications76 ............................................................ Breakdown77 Pre-Charge 78 Checking78 ............................................................. Charging79 Removal80 Installation80 ............................................................ MajorComponents81 ........................................................... HeaderDrivePump81 Removal81 Inspection82 ............................................................ Installation82 ............................................................ SpliterGearBox83 Disassembly83 Assembly85 ............................................................ AdjustmentInstructions90 .................................................... HeaderDriveSystemPressureAdjustment(ValveL-30)91 PumpFlow 97 HeaderLiftPump98 ......................................................... Removal98 Disassembly98 Inspection100 Assembly100 ........................................................... Installation103 AdjustmentInstructions104 HeaderLiftSystemPressureAdjustment(ValveL-03)105 .........................
SECTION35-HYDRAULICSYSTEMS
14
BOOK2-87742971 Chapter1-HydraulicSystems(Continued) CONTENTS SectionDescription Page AuxiliaryEngineMountedHydraulicPump(Optional)110 Removal110 Inspection110 ........................................................... Installation110 ........................................................... Start-upProcedure111 Maintenance111 CoolingCircuitBypassPressure112 ........................................ Temperatures112 ........................................................... Troubleshooting-Component113 General 113 ReducedSystemPressure113 ............................................ ReducedHydraulicFlow113 ............................................... ExcessiveNoise113 Overheating113 PowerLoss113 .......................................................... ExplanationofTermsUsedInFailureAnalysis114 ............................... PartsEvaluation115 Discoloration115 ScratchesorGrooves115 ................................................. Rework 115 RepeatFailures115 HeaderDriveSystem116 ..................................................... HeaderDrivePump118 HeaderDriveMotor119 ...................................................... ChargePump120 ServiceTechniques121 ...................................................... General121 OilLevel121 HosesandTubes122 ORingFlatFaceSealFittings122 ORingFlatFaceSealFittingTorqueValues122 Adjustments 123 HeaderDriveMotors123 Sauer-DanfossAuthorizedServiceCenters-NorthAmerica124
SECTION35-HYDRAULICSYSTEMS

SECTION35-HYDRAULICSYSTEMS

15
BOOK2-87742971
CONTENTS SectionDescription Page TiltCylinder128 Removal128 ............................................................ Inspection132 Assembly132 ........................................................... LiftCylinders136 Removal136 ............................................................ Inspection140 Assembly140 ........................................................... Zero-LeakPlugs144 Removal144 Install 144 PlugTorqueRequirements145 Zero-LeakPlugtoSAEJ514ORBPlugCrossReference145 HydraulicReservoirReplacement146 Removal146 ............................................................ Installation147 Troubleshooting-System149 .................................................... HeaderDriveSystem149 FurtherTroubleshootingTips152 ...........................................
Chapter1-HydraulicSystems(Continued)
16 SECTION44-REARAXLE BOOK2-87742971 Chapter1-Non-SuspendedRearAxle CONTENTS SectionDescription Page Introduction 2 Overview 2 .................................................................. Specifications 3 SpecialTools 3 .................................................................. DescriptionofOperation4 ExtensionsandAxleTube4 ................................................... Adjustments 8 WheelWidth 8 ............................................................... ChannelWidths(SpindletoSpindle)8 AxleExtensionPosition8 Overhaul 9 Wheel,AxleShaftandHub9 Removal 9 Inspection11 Installation12 ............................................................ AxleSupportFork15 Removal15 ............................................................. Inspection15 Installation16 ............................................................ RearAxleExtension18 Removal18 ............................................................. Inspection19 Installation19 ............................................................ AxleTubeandCenterPivotPin20 Removal20 ............................................................. Inspection21 Installation22 ............................................................
17
BOOK2-87742971 Chapter2-SuspendedRearAxle CONTENTS SectionDescription Page Introduction 2 Overview 2 ..................................................................... SpecialTools 2 Specifications 3 .................................................................. DescriptionofOperation4 ExtensionsandAxleTubes4 .................................................. Adjustments 7 WheelWidth 7 ............................................................... ExtensionWidths(SpindletoSpindle)7 AxleExtensionPosition7 Overhaul 8 Wheel,AxleShaftandHub8 Removal 8 Inspection10 Installation11 ............................................................. AxleSupportFork13 Removal13 ............................................................. Inspection13 Installation14 ............................................................ Extension 15 Removal15 ............................................................. Inspection16 Installation17 ............................................................ AirSpring 18 Removal18 ............................................................. Inspection19 Installation20 ............................................................ AxleTubesandPivotPins21 Removal21 Inspection22 Installation23
SECTION44-REARAXLE
18 SECTION50-CLIMATECONTROL BOOK2-87742971 Chapter1-ClimateControl CONTENTS SectionDescription Page Specifications 4 Compressor 4 Refrigerant 4 ................................................................. RefrigerantOil4 .............................................................. SpecialTools 4 DescriptionofOperation5 TheBasicsofRefrigeration5 ................................................... AirConditioningProcess6 ..................................................... R134aRefrigerantInformation7 RefrigerantIngredients7 Lubricants7 .............................................................. Refrigerant(R134a)7 ...................................................... CabAirFlow 8 SystemComponents10 CompressorPump10 ........................................................ CompressorClutch(L-27)10 .................................................. AirConditioningFilters11 Removal/Replacement11 RecirculationFilter13 ........................................................ Removal14 CleaningwithAir15 Condenser 15 ............................................................... Receiver/Drier16 ............................................................ ExpansionValve17 ValveComponents17 Operation18 ............................................................ PortIdentification21 ...................................................... Evaporator 21 BlowerFan 21 DescriptionofOperation--ClimateControls22 ...................................... ControlPanelñManualTemperatureControl--(A-05)22 .......................... BlowerFanSwitch22 TemperatureControlSwitch22 ControlPanelñ(ATC)AutomaticTemperatureControl(ifequipped)23 ..............
19
BOOK2-87742971 Chapter1-ClimateControl(Continued) CONTENTS SectionDescription Page ControlOperationSpecifications23 ATCOperatorControls23 ON/OFF 23 ............................................................. LEDDisplay23 .......................................................... AUTO 23 DEF 23 FanUP/DOWN24 ....................................................... TemperatureUP/DOWN24 ................................................ EXT(ExternalTemperature)24 ECON(EconomyMode)24 Celsius/Fahrenheitbutton24 .................................................. CompressorProtectionSwitches25 ............................................ High-pressureCutoutSwitch(S-40)25 Low-pressureCutoutSwitch(S-39)25 TroubleshootingandServicingAirConditioningSystem26 ............................ GeneralSafetyandServicePrecautions26 ..................................... Cleanliness 27 PreliminaryTroubleshootingandTesting27 OperationalChecks27 .................................................... ATCTroubleshootingFaultCodeChart28 DisplayFaultCodes28 AdvancedDiagnostics31 ..................................................... DiagnosisChartsñAirConditioningSystem35 .................................. TestProcedure:StabilizingtheSystem39 TestPorts39 Pressure/TemperatureRelationships40 ........................................ LeakTesting40 .......................................................... Refilling 40 Contaminants41 General 41 .............................................................. PreventingMixingofServiceEquipment41 .................................. RefrigerantExtractionAndRecyclingEquipment41 UsingExtractionEquipment42 UsingRecyclingEquipment42 ............................................. Recyclingvs.Reclaiming42 ...............................................
SECTION50-CLIMATECONTROL

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