New Holland 555912001 Service Manual Download Page 1

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Part number 48142788

English
April 2017

SERVICE MANUAL

FR480 Forage Cruiser / FR550 Forage Cruiser /

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

FR850 Forage Cruiser

Tier 2

Forage Harvester

FR850 Forage Cruiser - From PIN 555912001 to 555923100

Printed

in U.S.A.

New

Holland is a trademark registered in the United States and many other countries,

owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

Summary of Contents for 555912001

Page 1: ...725912001 to 725923100 FR650 Forage Cruiser From PIN 735912001 to 735923100 FR780 Forage Cruiser From PIN 745912001 to 745923100 FR850 Forage Cruiser Tier 2 Forage Harvester FR850 Forage Cruiser From...

Page 2: ...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 FR850 Forage Cruiser Ve...

Page 3: ...B 725912001 725923100 North America F3H FE613F B007 FR650 Forage Cruiser Cursor 16 TIER 4B FINAL 735912001 735923100 North America F3JFE613A B005 FR780 Forage Cruiser Cursor 16 TIER 4B FINAL 745912001...

Page 4: ...ox and drive 14 1 Transmission 21 21 114 Mechanical transmission 21 1 21 120 Gearbox 21 2 21 130 Mechanical transmission external controls 21 3 21 100 Mechanical transmission lubrication system 21 4 2...

Page 5: ...Variable displacement pump 35 4 35 204 Remote control valves 35 5 35 300 Reservoir cooler and filters 35 6 35 359 Main control valve 35 7 35 350 Safety and main relief valves 35 8 35 600 High flow hyd...

Page 6: ...ake and exhaust system 55 5 55 988 Selective Catalytic Reduction SCR electrical system 55 6 55 012 Engine cooling system 55 7 55 013 Engine oil system 55 8 55 301 Alternator 55 9 55 426 Harvest materi...

Page 7: ...frame 58 1 58 900 Belt feeding 58 2 Product feeding 60 60 101 Feed roll 60 1 60 122 Length of cut gearbox 60 2 60 103 Lower feed rolls 60 3 60 107 Upper feed rolls 60 4 Chemical applicators 63 63 115...

Page 8: ...m 71 71 460 Grease lubrication system 71 1 Platform cab bodywork and decals 90 90 105 Machine shields and guards 90 1 90 150 Cab 90 2 90 151 Cab interior 90 3 48142788 28 04 2017 Find manuals at https...

Page 9: ...48142788 28 04 2017 Find manuals at https best manuals com...

Page 10: ...INTRODUCTION 48142788 28 04 2017 1 Find manuals at https best manuals com...

Page 11: ...Safety rules 13 Personal safety 16 Basic instructions Shop and assembly 17 Torque 19 Torque Standard torque data for hydraulic connections 22 Basic instructions Chain Wear Tables Roller Chains 29 Con...

Page 12: ...n that have been written for that function or system the technical data specifications the functional data how it works the diagnostic data fault codes and troubleshooting and the service data remove...

Page 13: ...to the main functions or a systems on the machine Each Section is identified by a number 00 35 55 etc The amount of Sections included in the manual will depend on the type and function of the machine...

Page 14: ...ation 73 Residue handling 74 Cleaning 75 Soil preparation Finishing 76 Secondary cleaning Destemmer 77 Seeding 78 Spraying 79 Planting 80 Crop storage Unloading 82 Front loader and bucket 83 Telescopi...

Page 15: ...tion for that function is included Hitches drawbars and implement couplings 37 Frames and ballasting 39 Steering 41 Wheels 44 Steering clutches 46 Tracks and track suspension 48 Cab climate control 50...

Page 16: ...oms dippers and buckets 84 Dozer blade and arm 86 Accessories 88 Tools 89 Platform cab bodywork and decals 90 This Section covers all the main functions and systems related to the body of the machine...

Page 17: ...emove install adjust etc and diagnostic data fault codes and troubleshooting that have been written in that Chapter for that function or system on the machine Contents HYDRAULIC SYSTEMS 35 Main contro...

Page 18: ...information unit Main control valve Sectional View 35 359 Information Unit SAP code 35 Hydraulic systems SAP code classification 359 Main control valve Page header and footer The page header will con...

Page 19: ...local dealers reject any responsibility for damages caused by parts and or components not approved by the manu facturer including those used for the servicing or repair of the product manufactured or...

Page 20: ...e 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 p...

Page 21: ...ies with all local legislation and available resources Do not allow coolant mixtures to get into the soil Collect and dispose of coolant mixtures properly The air conditioning system contains gases th...

Page 22: ...o comply could result in minor or moderate injury C0038A SAFETY REQUIREMENTS FOR FLUID POWER SYSTEMS AND COMPONENTS HY DRAULICS Flexible hose assemblies must not be constructed from hoses which have b...

Page 23: ...similar equipment must only be powered by auxiliary power supplies with efficient ground insulation to avoid electrical shock hazards Always use suitable hoisting or lifting devices when raising or mo...

Page 24: ...ause damage to the wheel Never cut or weld a rim mounted with an inflated tire Deflate the tire before removing any objects that may be jammed in the tire tread Never inflate tires using inflammable g...

Page 25: ...stance 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 fu...

Page 26: ...in its seat and press down using a flat punch or seal installation tool Do not tap the seal with a hammer or mallet 6 While you insert the seal check that the seal is perpendicular to the seat When t...

Page 27: ...attery ground cable from the machine battery The electronic monitoring system and charging system will be damaged if this is not done 5 Remove the battery ground cable Reconnect the cable when you com...

Page 28: ...N m 89 4 lb in 5 5 N m 48 7 lb in 9 1 N m 80 5 lb in 14 5 N m 10 7 lb ft 7 9 N m 69 9 lb in 13 N m 9 6 lb ft M8 24 5 N m 18 1 lb ft 13 5 N m 10 0 lb ft 22 N m 16 2 lb ft 35 1 N m 25 9 lb ft 19 3 N m 1...

Page 29: ...ut Lock nut Hardened nut M27 1073 N m 791 4 lb ft 590 1 N m 435 2 lb ft 967 5 N m 713 6 lb ft 1486 N m 1096 lb ft 817 3 N m 602 8 lb ft 1337 N m 986 1 lb ft M30 1461 N m 1077 6 lb ft 803 5 N m 592 6 l...

Page 30: ...INTRODUCTION ZEIL06CS0135F0A 3 48142788 28 04 2017 21...

Page 31: ...he torque wrench repeatability Lubrication Application of grease or other lubricants to hydraulic connectors should be avoided If clean hydraulic oil is already on the connection it is not required to...

Page 32: ...7 220 162 3 132 97 4 M48 x 2 440 324 5 264 194 7 273 201 4 164 121 M60 x 2 525 387 2 315 232 3 330 243 4 198 146 S Series connectors are used with O Ring Face Seals ORFS L Series connectors are used w...

Page 33: ...Face Seals ORFS L Series connectors are used with 37 flare Torque values for metric port connections Metric face seal ports and stud ends Metric tube Outside Diameter OD mm in Ferrous Non Ferrous Metr...

Page 34: ...Series connectors are used with O Ring Face Seals ORFS L Series connectors are used with 37 flare Torque values for inch O Ring Boss ORB port adjustable connections S Series L Series SAE dash size UN...

Page 35: ...25 1 M8 x 1 25 34 25 1 19 3 4 M10 x 1 5 74 54 6 M10 x 1 5 74 54 6 25 1 M10 x 1 5 74 54 6 M12 x 1 75 137 101 M12 x 1 75 137 101 32 1 1 4 M10 x 1 5 74 54 6 M14 x 1 5 189 139 4 38 1 1 2 M12 x 1 75 137 1...

Page 36: ...0 228 6 127 5 5 8 11 310 228 6 Tapered thread connection tightening British Standard Pipe Taper BSPT thread size inch National Pipe Thread Fuel NPTF thread size inch Turns from finger tight 1 8 28 1 8...

Page 37: ...connection instead of O Ring Face Seals ORFS sizes 16 and up Torque values for 37 flare connections Joint Industry Council JIC SAE dash size UN UNF thread size Metric tube OD mm Inch tube OD mm Swive...

Page 38: ...he material and surface condition of the bearing surfaces the adequacy of lubrication and the frequency and degree of articulation between pins and bushings The latter is determined by the quantity of...

Page 39: ...in 1143 mm 45 0 in 1177 mm 46 3 in 1524 mm 60 0 in 1568 mm 61 7 in 70P 889 mm 35 0 in 914 mm 36 0 in 1111 mm 43 7 in 1144 mm 45 0 in 1333 mm 52 5 in 1371 mm 54 0 in 1778 mm 70 0 in 1828 mm 72 0 in 80...

Page 40: ...S gal 1 US gal 3 78 litre 1 litre 0 0 28 Bu 1 Bu 35 23 litre 1 litre 1 057 US quart 1 US quart 0 9464 litre 1 cm cc 0 061 in 1 in 16 38 cm cc 1 m 35 31 ft 1 ft 0 028 m 1 ml 0 033 US fl oz 1 US fl oz 2...

Page 41: ...reverse 0 s A1001 Metal detector is not responding The metal detector does not activate its stop output when requested Check harness Yellow Main clutch on AND Electro magnetic Metal Detector EMD is no...

Page 42: ...s Engine not running OR pressure switch closed 0 5 s A1105 Header hydro oil pressure low The pressure in the header hydrostatic system is too low Check oil level Red Engine running AND pressure switch...

Page 43: ...osition Start sharpening procedure to bring the stone home Yellow Sharpening not ongoing AND engaging main clutch AND stone not in home position 0 s Sharpening ongoing OR main clutch Off OR stone in h...

Page 44: ...down Yellow Temperature 105 C 10 s Temperature 100 C 3 s A2004 Ground drive hydro oil pressure low The pressure in the ground drive hydrostatic system is too low Check oil level Red Engine running AN...

Page 45: ...de activated Carefully drive the machine Apply foot brakes immediately in case of irregular driving behavior Stop driving to allow deactivation press Deactiv Yellow Ground drive pump Failure Mode Indi...

Page 46: ...ne shut off Low engine oil pressure Restart at own risk by holding the throttle down switch during cranking Red Engine running AND engine shutdown request from engine oil pressure 0 s Time out 60 s A2...

Page 47: ...ator OR slow down Yellow Cursor engines temperature 123 C 3 s Cursor engines temperature 123 C 3 s A2125 Engine oil pressure low The pressure of the engine oil is too low Red From engine 0 s From engi...

Page 48: ...ellow Fuel level 3 2 s Fuel level 3 5 s A2201 Water in fuel Water has been detected in the fuel prefilter Yellow Water in fuel 5 s No water in fuel 2 s A2202 Engine fuel filter clogged Replace fuel fi...

Page 49: ...engagement OR main pulley speed zero 4 s A3001 Engine speed not reached The engine did not reach the desired speed Try again White Main clutch OR reverse clutch engagement AND engine speed not reache...

Page 50: ...rmal operation White Clutch engagement request when service area shielding is open 2 s Time out 4 s A3100 CM3 Back feed voltage detected Harness problem Red At key on main relay is Off AND back feed v...

Page 51: ...AND pressure 0 5 bar 5 s Engine not running OR pressure 0 5 bar 2 s A3207 Greasing level low Add grease A3208 Greasing obstruction An obstruction is found in the greasing system Tighten the quick coup...

Page 52: ...id AND tank level 5 10 s Additives system enabled OR not in field mode OR additives system manual AND additive system automatic AND tank level 5 5 s A3216 Additives flow not reachable The pump is at i...

Page 53: ...zle white AND requested fixed flow 38 l hour OR 150 l hour OR selected nozzle green AND requested fixed flow 45 l hour OR 200 l hour 10 s Additives system enabled OR not in field mode OR additives sys...

Page 54: ...not detected Module not detected after power on A5011 RHM communication lost Module has been detected but is lost now A5012 SAM not detected Module not detected after power on A5013 SAM communication...

Page 55: ...lost now Module found A5029 ATCM not detected Module not detected after power on A5030 ATCM communication lost Recycle power See operator s manual if problem continues White Module has been detected b...

Page 56: ...ll 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 automati...

Page 57: ...ressure low A2004 ON OFF pressure switch goes ON when pressure low CM does not read pressure value 5 bar 73 psi 0 s 1 s 2 s Engine oil pressure low A2125 CAN message from ECU goes ON when engine oil p...

Page 58: ...2208 CAN message from ECU goes on when rail pressure low CM does not know pressure value Curve speed dependant Curve speed dependant Curve speed dependant 0 s 1 s 7 s Engine rail pressure high A2209 C...

Page 59: ...indicates the product line CR CX CS CSX Combine Harvesters 1 TC Combine Harvesters 9 Combine Headers 9 Forage Harvesters 5 Grass Pickup 3 Square Balers 4 725 902 002 These three digits indicate the ba...

Page 60: ...g the direction of travel during working operation The following overhead view illustration is a general representation of the machine The illustration indicates the sides front and rear orientations...

Page 61: ...INTRODUCTION 48142788 28 04 2017 52...

Page 62: ...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: ...uel tanks 10 2 10 218 Fuel injection system 10 3 10 400 Engine cooling system 10 4 10 414 Fan and drive 10 5 10 418 Rotary screen 10 6 10 304 Engine lubrication system 10 7 10 500 Selective Catalytic...

Page 64: ...1 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 65: ...Contents Engine 10 Engine and crankcase 001 SERVICE Engine Remove 3 Install 20 See content for specific models 48142788 28 04 2017 10 1 10 001 2...

Page 66: ...or its components is pos sible DO NOT work under a vehicle supported by jack stands only Park machine on a level surface Block wheels Support machine with safety stands Failure to comply could result...

Page 67: ...strut 3 then remove the gas strut 3 from the pivot bolt Remove the hardware 1 Remove the rear shield 2 ZEIL15FR00085AA 2 6 Remove the hardware 4 six in total and remove the top rear shield 5 ZEIL15FR...

Page 68: ...open the tap and drain fluid NOTE Still some coolant in the tubes ZEIL15FR00088AA 6 ZEIL15FR00089AA 7 Wiring harnesses 10 On the left hand side of the machine remove all the straps and disconnect all...

Page 69: ...the machine remove all the straps and disconnect all the connectors of the wiring harness branch see arrow going down of the wiring harness 6 and lay the wiring harness branch on top of the roof assem...

Page 70: ...14 from the engine coolant intake tube 19 Disconnect the Diesel Exhaust Fluid DEF Ad Blue injector coolant lines 15A and 15B See also Figure 15 20 Remove the NOx sensor 13 from the exhaust 21 Remove t...

Page 71: ...m the heater valve ZEIL15FR00102AA 17 27 On the left hand side of the machine remove the hardware 21 and carefully pull the DEF AdBlue coolant lines and the DEF AdBlue feed line 15 through the hole Se...

Page 72: ...he side shieldings and use the spout support as shown ZEIL15FR00116AA 21 32 On the left hand side of the machine remove the hardware 29 ZEIL15FR00117AA 22 33 Remove the hardware 31 ZEIL15FR00198AA 23...

Page 73: ...15FR00120AA 26 37 Remove the hardware 33 ZEIL15FR00119AA 27 38 Make sure nothing remains connected to the roof as sembly Remove the roof assembly NOTE Make sure that the chains are set in such a way t...

Page 74: ...amp 39 of the engine air intake tube 38 43 On the engine loosen the clamp 39 of the engine air intake tube 38 at the engine air intake piece not shown 44 Remove the clamp hardware 40 45 Remove the pig...

Page 75: ...coolant ZEIL15FR00145AA 33 50 Loosen the hose clamp 47 51 Remove the clamps 48 and remove the breather tube 26 ZEIL15FR00139AA 34 52 Loosen the hose clamp 49 of the engine coolant inlet tube 50 53 Rem...

Page 76: ...ardware 55 ZEIL15FR00127AA 38 59 On the left hand side of the machine under the main gearbox clutch shaft remove the hardware 56 and the support 57 ZEIL15FR00128AA 39 60 Release the tension of the fan...

Page 77: ...ire harness 7 See also Figure 45 NOTE Connectors 7B and 7E are connected to the pressure sensors who can only be found on machines with variable displacement hydro motor These machines have a maximum...

Page 78: ...FR00133AA 45 70 Remove the hose 77 the hose 81 the hose 78 the hose 79 and the hose 80 ZEIL15FR00132AA 46 71 Remove the clamp hardware 82 Disconnect the tube 83 ZEIL15FR00146AA 47 72 Remove the clamp...

Page 79: ...rear right hand side of the machine Remove the hardware 84 ZEIL15FR00155AA 50 75 On the rear right hand side light cover 86 Remove the plastic rivet 85 ZEIL15FR00156AA 51 76 Remove the hardware 87 and...

Page 80: ...rame 88 ZEIL15FR00159AA 54 Engine supports fuel and air conditioning lines 81 Loosen the hose clamp 27 and remove the rubber elbow coupler 28 ZEIL15FR00149AA 55 82 Support the engine on all three poin...

Page 81: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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