New Holland H8060 Service Manual

SERVICE MANUAL
H8060 / H8080
Self-Propelled Windrower
from PIN YCG667001 and above
Part number 47487696
1st edition English
January 2013
Printed in U.S.A.
Copyright © 2013 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC.
Racine Wisconsin 53404 U.S.A.
Contents
INTRODUCTION
Engine....................................................................................... 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
Front axle system ....................................................................... 25
[25.310] Final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1
Rear axle system........................................................................ 27
[27.550] Non-powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1
Hydrostatic drive......................................................................... 29
[29.100] Transmission and steering hydrostatic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.1
[29.202] Hydrostatic transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.2
[29.218] Pump and motor components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.3
Power Take-Off (PTO) ................................................................. 31
[31.226] Hydraulic pump drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1
Brakes and controls .................................................................... 33
[33.110] Parking brake / Parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1
Hydraulic systems....................................................................... 35
[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1
[35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2
[35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3
[35.105] Charge pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4
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[35.300] Reservoir, cooler, and filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5
[35.565] Cutter control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6
[35.910] Draper header hydraulic drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7
Steering..................................................................................... 41
[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1
Wheels ...................................................................................... 44
[44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1
Cab climate control ..................................................................... 50
[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1
[50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2
[50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3
Electrical systems ....................................................................... 55
[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1
[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2
[55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3
[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4
[55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5
[55.019] Hydrostatic drive control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6
[55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7
[55.050] Heating, Ventilation, and Air-Conditioning (HVAC) control system. . . . . . . . . . . . . . . . . 55.8
[55.051] Cab Heating, Ventilation, and Air-Conditioning (HVAC) controls. . . . . . . . . . . . . . . . . . . 55.9
[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10
[55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11
[55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12
[55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.13
[55.512] Cab controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.14
[55.518] Wiper/Washer system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.15
[55.520] Cab harvesting controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.16
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[55.634] Merger electrical control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.17
[55.661] Cab header controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.18
[55.662] Header height control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.19
[55.830] Rotary screen drive and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.20
[55.DTC] FAULT CODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.21
Attachments/Headers.................................................................. 58
[58.110] Attachment/Header cutting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.1
[58.130] Attachment/Header frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.2
Platform, cab, bodywork, and decals ............................................. 90
[90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1
[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2
[90.151] Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3
[90.154] Cab doors and hatches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4
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INTRODUCTION
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Contents
INTRODUCTION
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
[YCG667001-], H8060, [YCG667001-], H8080
Note to the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
[YCG667001-], H8060, [YCG667001-], H8080
Foreword - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
H8000
Personal safety - Do not operate tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Basic instructions - Hydraulic contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
16
17
21
23
25
[YCG667001-], [YCG667001-]
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
[YCG667001-], [YCG667001-]
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
[YCG667001-], [YCG667001-]
General specification - Biodiesel Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
[YCG667001-], [YCG667001-]
Product overview - Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
[YCG667001-], [YCG667001-]
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INTRODUCTION
Basic instructions - Important notice regarding equipment servicing
[YCG667001-], H8060, [YCG667001-], H8080
All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for
continuous improvement. Some information could not be updated due to modifications of a technical or commercial
type, or changes to the laws and regulations of different countries.
In case of questions, refer to your NEW HOLLAND AGRICULTURE Sales and Service Networks.
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INTRODUCTION
Note to the Owner
COMPANY POLICY
Company policy, which is one of continuous improvement, reserves the right to make changes in design and specifications at any time without notice and without obligation to modify units previously built.
All data given in this book is subject to production variations. Dimensions and weights are approximate only and the
illustrations do not necessarily show windrowers in standard condition.
PARTS AND ACCESSORIES
Genuine NEW HOLLAND AGRICULTURE parts and accessories have been specifically designed for NEW HOLLAND
AGRICULTURE MACHINES.
We would like to point out those "NON-GENUINE" parts and accessories have not been examined and released by
NEW HOLLAND AGRICULTURE. The installation and or use of such products could have negative effects upon the
design characteristics of your machine and thereby affect its safety. NEW HOLLAND AGRICULTURE is not liable for
any damage caused by the use of "NON-GENUINE" NEW HOLLAND AGRICULTURE parts and accessories.
LUBRICATION
Adequate lubrication and maintenance on a regular schedule is vital to maintaining your equipment. To ensure long
service and efficient operation, follow the lubrication and maintenance schedules outlined in this manual. The use of
proper fuels, oils, grease and filters, as well as keeping the systems clean, will also extend machine and component
life.
NOTICE: Always use genuine NEW HOLLAND AGRICULTURE replacement parts, oils and filters to ensure proper
operation, filtration of engine and hydraulic systems. See your NEW HOLLAND AGRICULTURE dealer for additional
oil quantities.
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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 instructions. These precautions are intended for the personal safety of you and those working with you.
Read and understand all the safety messages in this manual before you operate or service the machine.
DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT
IN DEATH OR SERIOUS INJURY.
Machine safety
NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.
Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or
property damage. The word Notice is used to address practices not related to personal safety.
Information
NOTE: Note indicates additional information that clarifies steps, procedures, or other information in this manual.
Throughout this manual you will find the word Note followed by additional information about a step, procedure, or
other information in the manual. The word Note is not intended to address personal safety or property damage.
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INTRODUCTION
Safety rules
[YCG667001-], H8060, [YCG667001-], H8080
General safety rules
Use caution when operating the machine on slopes. Raised equipment, full tanks and other loads will change the
center of gravity of the machine. The machine can tip or roll over when near ditches and embankments or uneven
surfaces.
Never permit anyone other than the operator to ride on the machine.
Never operate the machine under the influence of alcohol, drugs, or while otherwise impaired.
When digging or using ground engaging attachments be aware of buried cables. Contact local utilities to determine
the locations of services.
Pay attention to overhead power lines and hanging obstacles. High voltage lines may require significant clearance
for safety.
Hydraulic oil or diesel fuel leaking under pressure can penetrate the skin, causing serious injury or infection.
• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper.
• Stop engine, remove key and relieve the pressure before connecting or disconnecting fluid lines.
• Make sure all components are in good condition and tighten all connections before starting the engine or pressurizing the system.
• If hydraulic fluid or diesel fuel penetrates the skin, seek medical attention immediately.
• Continuous long term contact with hydraulic fluid may cause skin cancer. Avoid long term contact and wash the
skin promptly with soap and water.
Keep clear of moving parts. Loose clothing, jewelry, watches, long hair, and other loose or hanging items can become
entangled in moving parts.
Wear protective equipment when appropriate.
DO NOT attempt to remove material from any part of the machine while it is being operated or components are in
motion.
Make sure all guards and shields are in good condition and properly installed before operating the machine. Never
operate the machine with shields removed. Always close access doors or panels before operating the machine.
Dirty or slippery steps, ladders, walkways, and platforms can cause falls. Make sure these surfaces remain clean and
clear of debris.
A person or pet within the operating area of a machine can be struck or crushed by the machine or its equipment. DO
NOT allow anyone to enter the work area.
Raised equipment and/or loads can fall unexpectedly and crush persons underneath. Never allow anyone to enter
the area underneath raised equipment during operation.
Never operate engine in enclosed spaces as harmful exhaust gases may build up.
Before starting the machine, be sure that all controls are in neutral or park lock position.
Start the engine only from the operator’s seat. If the safety start switch is bypassed, the engine can start with the
transmission in gear. Do not connect or short across terminals on the starter solenoid. Attach jumper cables as
described in the manual. Starting in gear may cause death or serious injury.
Always keep windows, mirrors, all lighting, and Slow Moving Vehicle (SMV) emblem clean to provide the best possible
visibility while operating the machine.
Operate controls only when seated in the operator’s seat, except for those controls expressly intended for use from
other locations.
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INTRODUCTION
Before leaving the machine:
1. Park machine on a firm level surface.
2. Put all controls in neutral or park lock position.
3. Engage park brake, use wheel chocks if required.
4. Lower all hydraulic equipment — Implements, header, etc.
5. Turn off engine and remove key.
When, due to exceptional circumstances, you would decide to keep the engine running after leaving the operator’s
station, then the following precautions must be followed:
1. Bring the engine to low idle speed.
2. Disengage all drive systems.
3.
WARNING
Some components may continue to run down after disengaging drive systems.
Make sure all drive systems are fully disengaged.
Failure to comply could result in death or serious injury.
W0113A
Shift the transmission into neutral.
4. Apply the parking brake.
General maintenance safety
Keep area used for servicing the machine clean and dry. Clean up spilled fluids.
Service machine on a firm level surface.
Install guards and shields after servicing the machine.
Close all access doors and install all panels after servicing the machine.
Do not attempt to clean, lubricate, clear obstructions or make adjustments to the machine while it is in motion or while
the engine is running.
Always make sure working area is clear of tools, parts, other persons and pets before you start operating the machine.
Unsupported hydraulic cylinders can lose pressure and drop the equipment causing a crushing hazard. Do not leave
equipment in a raised position while parked or during service, unless securely supported.
Jack or lift the machine only at jack or lift points indicated in this manual.
Incorrect towing procedures can cause accidents. When towing a disabled machine follow the procedure in this manual. Use only rigid tow bars.
Stop the engine, remove key and relieve pressure before disconnecting or connecting fluid lines.
Stop the engine and remove key before disconnecting or connecting electrical connections.
Scalding can result from incorrect removal of coolant caps. Cooling system operates under pressure. Hot coolant
can spray out if a cap is removed while the system is hot. Allow system to cool before removing cap. When removing
a cap turn it slowly to allow pressure to escape before completely removing the cap.
Replace damaged or worn tubes, hoses, electrical wiring, etc.
Engine, transmission, exhaust components, and hydraulic lines may become hot during operation. Take care when
servicing such components. Allow surfaces to cool before handling or disconnecting hot components. Wear protective
equipment when appropriate.
When welding, follow this instructions in the manual. Always disconnect the battery before welding on the machine.
Always wash your hands after handling battery components.
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INTRODUCTION
Wheels and tires
Make sure tires are correctly inflated. Do not exceed recommended load or pressure. Follow instructions in the
manual for proper tire inflation.
Tires are heavy. Handling tires without proper equipment could cause death or serious injury.
Never weld on a wheel with a tire installed. Always remove tire completely from wheel prior to welding.
Always have a qualified tire technician service the tires and wheels. If a tire has lost all pressure, take the tire and
wheel to a tire shop or your dealer for service. Explosive separation of the tire can cause serious injury.
DO NOT weld to a wheel or rim until the tire is completely removed. Inflated tires can generate a gas mixture with
the air than can be ignited by high temperatures from welding procedures performed on the wheel or rim. Removing
the air or loosening the tire on the rim (breaking the bead) will NOT eliminate the hazard. This condition can exist
whether tires are inflated or deflated. The tire MUST be completely removed from the wheel or rim prior to welding
the wheel or rim.
Driving on public roads and general transportation safety
Comply with local laws and regulations.
Use appropriate lighting to meet local regulations.
Make sure SMV emblem is visible.
Use safety chains for trailed equipment when provided with machine or equipment.
Lift implements and attachments high enough above ground to prevent accidental contact with road.
When transporting equipment or machine on a transport trailer, make sure it is properly secured. Be sure the SMV
on the equipment or machine is covered while being transported on a trailer.
Be aware of overhead structures or power lines and make sure the machine and/or attachments can pass safely
under.
Travel speed should be such that complete control and machine stability is maintained at all times.
Slow down and signal before turning.
Pull over to allow faster traffic to pass.
Follow correct towing procedure for equipment with or without brakes.
Fire and explosion prevention
Fuel or oil leaked or spills on hot surfaces or electrical components can cause a fire.
Crop materials, trash, debris, bird nests, or flammable material can ignite on hot surfaces.
Always have a fire extinguisher on or near the machine.
Make sure the fire extinguisher(s) is maintained and serviced according to the manufacturer’s instructions.
At least once each day and at the end of the day remove all trash and debris from the machine especially around
hot components such as engine, transmission, exhaust, battery, etc. More frequent cleaning of your machine may be
necessary depending on the operating environment and conditions.
At least once each day, remove debris accumulation around moving components such as bearings, pulleys, belts,
gears, cleaning fan, etc. More frequent cleaning of your machine may be necessary depending on the operating
environment and conditions.
Inspect the electrical system for loose connections or frayed insulation. Repair or replace loose or damaged parts.
47487696 17/01/2013
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INTRODUCTION
Do not store oily rags or other flammable material on the machine.
Do not weld or flame cut any items that contain flammable material. Clean items thoroughly with non-flammable
solvents before welding or flame-cutting.
Do not expose the machine to flames, burning brush, or explosives.
Promptly investigate any unusual smells or odors that may occur during operation of the machine.
General battery safety
Always wear eye protection when working with batteries.
Do not create sparks or have open flame near battery.
Ventilate when charging or using in an enclosed area.
Disconnect negative (-) first and reconnect negative (-) last.
When welding on the machine, disconnect both terminals of the battery.
Do not weld, grind, or smoke near a battery.
When using auxiliary batteries or connecting jumper cables to start the engine, use the procedure shown in the operator’s manual. Do not short across terminals.
Follow manufacturer’s instructions when storing and handling batteries.
Battery post, terminals, and related accessories contain lead and lead compounds. Wash hands after handling. This
is a California Proposition 65 warning.
Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately.
Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Keep out of reach of children and other unauthorized persons.
Instructional seat safety
Passengers are not permitted to ride on the machine.
The instructional seat is to be used only when training a new operator or when a service technician is diagnosing a
problem.
When required for the purposes of training or diagnostics, only one person may accompany the operator and that
person must be seated in the instructional seat.
When the instructional seat is occupied, the following precautions must be followed:
• Machine should be driven only at slow speeds and over level ground.
• Avoid driving on highways or public roads.
• Avoid quick starts or stops.
• Avoid sharp turns.
• Always wear correctly adjusted seat belts.
• Keep door closed at all times.
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INTRODUCTION
Operator presence system
Your machine is equipped with an operator presence system to prevent the use of some features while the operator
is not in the operator’s seat.
The operator presence system should never be disconnected or bypassed.
If the system is inoperable, the system must be repaired.
Power Take-Off (PTO)
PTO-driven machinery can cause death or serious injury. Before working on or near the PTO shaft or servicing or
clearing the driven machine, put the PTO lever in the disengage position, stop the engine, and remove the key.
Whenever a PTO is in operation, a guard must be in place to prevent death or injury to the operator or bystanders.
When doing stationary PTO work, keep clear of all moving parts and make sure appropriate guards are in place.
Reflectors and warning lights
Reflectors are located on the handrails in the areas as shown in Figure 1.
Flashing amber warning lights must be used when operating on public roads.
86070769
1
Seat belts
Seat belts must be worn at all times.
Seat belt inspection and maintenance:
• Keep seat belts in good condition.
• Keep sharp edges and items than can cause damage away from the belts.
• Periodically check belts, buckles, retractors, tethers, slack take-up system, and mounting bolts for damage.
• Replace all parts that have damage or wear.
• Replace belts that have cuts that can make the belt weak.
• Check that bolts are tight on the seat bracket or mounting.
• If belt is attached to seat, make sure seat or seat brackets are mounted securely.
• Keep seat belts clean and dry.
• Clean belts only with soap solution and warm water.
• Do not use bleach or dye on the belts because this can make the belts weak.
To fasten the belt, pull it from the reel and push the tongue end (1) into the buckle end (2) until a "click" indicates it is
fully engaged.
47487696 17/01/2013
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INTRODUCTION
To release the belt, push the red release button (3) on the buckle and pull the tongue from the buckle.
10041220
2
Air-conditioning system
The air-conditioning system is under high pressure. Do not disconnect any lines. The release of high pressure can
cause serious injury.
The air-conditioning system contains gases that are harmful to the environment when released into the atmosphere.
Do not attempt to service or repair the system.
Service, repair, or recharging must be performed only by a trained service technician.
Personal Protective Equipment (PPE)
Wear Personal Protective Equipment (PPE) such as hard hat, eye protection, heavy gloves, hearing protection, protective clothing, etc.
Do Not Operate tag
Before you start servicing the machine, attach a ‘Do Not Operate’ warning tag to the machine in an area that will be
visible.
Hazardous chemicals
If you are exposed to or come in contact with hazardous chemicals you can be seriously injured. The fluids, lubricants,
paints, adhesives, coolant, etc. required for the function of your machine can be hazardous. They may be attractive
and harmful to domestic animals as well as humans.
Material Safety Data Sheets (MSDS) provide information about the chemical substances within a product, safe handling and storage procedures, first aid measures and procedures to be taken in the event of a spill or accidental
release. MSDS are available from your dealer.
Before you service your machine check the MSDS for each lubricant, fluid, etc. used in this machine. This information
indicates the associated risks and will help you service the machine safely. Follow the information in the MSDS, on
manufacturer containers, as well as the information in this manual when servicing the machine.
Dispose of all fluids, filters, and containers in an environmentally safe manner according to local laws and regulations.
Check with local environmental and recycling centers or your dealer for correct disposal information.
Store fluids and filters in accordance with local laws and regulations. Use only appropriate containers for the storage
of chemicals or petrochemical substances.
Keep out of reach or children or other unauthorized persons.
Additional precautions are required for applied chemicals. Obtain complete information from the manufacturer or
distributor of the chemicals before using them.
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INTRODUCTION
Utility safety
When digging or using ground-engaging equipment, be aware of buried cables and other services. Contact your local
utilities or authorities, as appropriate to determine the locations of services.
Make sure the machine has sufficient clearance to pass in all directions. Pay special attention to overhead power
lines and hanging obstacles. High voltage lines may require significant clearance for safety. Contact local authorities
or utilities to obtain safe clearance distances from high voltage power lines.
Retract raised or extended components, if necessary. Remove or lower radio antennas or other accessories. Should
a contact between the machine and an electric power source occur, the following precautions must be taken:
• Stop the machine movement immediately.
• Apply the park brake, stop the engine, and remove the key.
• Check if you can safely leave the cab or your actual position without contact with electrical wires. If not, stay in your
position and call for help. If you can leave your position without touching lines, jump clear of the machine to make
sure you do not make contact with the ground and the machine at the same time.
• Do not permit anyone to touch the machine until power has been shut off to the power lines.
Working at heights
When the normal use and maintenance of the machine requires working at heights:
• Correctly use installed steps, ladders, and railings.
• Never use ladders, steps, or railings while the machine is moving.
• Do not stand on surfaces which are not designated as steps or platforms.
Do not use the machine as a lift, ladder, or platform for working at heights.
Lifting and overhead loads
Never use lifting or handling equipment to lift persons.
Do not used raised equipment as a work platform.
Know the full area of movement of the machine and equipment and do not enter or permit anyone to enter the area
of movement while the machine is in operation.
Never enter or permit anyone to enter the area underneath raised equipment. Equipment and/or loads can fall unexpectedly and crush persons underneath it.
Do not leave equipment in raised position while parked or during service, unless securely supported. Hydraulic cylinders must be mechanically locked or supported if they are left in a raised position for service or access.
Headers or other lifting and handling equipment and its load will change the center of gravity of the machine. This
can cause the machine to top on slopes or uneven ground.
Load items can fall off the lifting equipment and crush the operator. Care must be taken when lifting a load. Use
proper lifting equipment.
Do not lift load higher than necessary. Lower loads to transport. Remember to leave appropriate clearance to the
ground and other obstacles.
Equipment and associated loads can block visibility and cause an accident. Do not operate with insufficient visibility.
Mounting and dismounting
Mount and dismount the machine only at designated locations that have handholds, steps, or ladders.
Do not jump off the machine.
47487696 17/01/2013
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INTRODUCTION
Make sure steps, ladders, and platforms remain clean and clear of debris and foreign substances. Injury may result
from slippery surfaces.
Face the machine when mounting and dismounting.
Maintain a three-point contact with steps, ladders, and handholds.
Never mount or dismount from a moving machine.
Do not use the steering wheel or other controls or accessories as handholds when entering or exiting the cab or
operator’s platform.
Header lift locks
Do not work under the machine header unless it is securely blocked and/or the header safety latch is engaged.
Header will fall rapidly if hydraulic lift system should fall.
Rest header on ground or engage lift cylinder lockouts when working around raised header.
The header lift locks are engaged on the left-hand side of the machine by pushing handle rearward.
NHIL12WR00239AA
3
47487696 17/01/2013
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INTRODUCTION
Foreword - Ecology and the environment
H8000
Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment
of some of the substances required by advanced technology, sound judgment should govern the use and disposal of
products of a chemical and petrochemical nature.
NOTE: The following are recommendations that may be of assistance:
• Become acquainted with and ensure that you understand the relative legislation applicable to your country.
• Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these
substances.
• Agricultural consultants will, in many cases, be able to help you as well.
Helpful hints
• Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable
spillage.
• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be
harmful to your health.
• Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.
• Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper
way to comply with local legislation and available resources.
• Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not
be allowed to get into the soil, but should be collected and disposed of properly.
• Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere.
Your NEW HOLLAND AGRICULTURE dealer or air conditioning specialist has a special extractor for this purpose
and will have to recharge the system properly.
• Repair any leaks or defects in the engine cooling or hydraulic system immediately.
• Do not increase the pressure in a pressurized circuit as this may lead to a component failure.
• Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of
oils, coolant, etc.
47487696 17/01/2013
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INTRODUCTION
Personal safety - Do not operate tag
WARNING
Avoid injury! Always do the following before lubricating, maintaining, or servicing the machine.
1. Disengage all drives.
2. Engage parking brake.
3. Lower all attachments to the ground, or raise and engage all safety locks.
4. Shut off engine.
5. Remove key from key switch.
6. Switch off battery key, if installed.
7. Wait for all machine movement to stop.
Failure to comply could result in death or serious injury.
W0047A
Before you service the machine, put a DO NOT OPERATE tag on the instrument panel.
321_4614
1
DO NOT OPERATE TAG
A. (1) Do not operate.
B. (2) Do not remove this.
C. (3) See other side.
D. (4) Signed by.
E. (5) Reason
The DO NOT OPERATE tag can be obtained from your NEW HOLLAND AGRICULTURE dealer.
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INTRODUCTION
Safety rules
BT09A213
1
47487696 17/01/2013
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INTRODUCTION
Torque - Minimum tightening torques for normal assembly
METRIC NON-FLANGED HARDWARE
NOM.
SIZE
CLASS 8.8 BOLT and
CLASS 8 NUT
PLATED
UNPLATED
W/ZnCr
M4
M5
M6
M8
2.2 N·m (19 lb
in)
4.5 N·m (40 lb
in)
7.5 N·m (66 lb
in)
18 N·m (163 lb
in)
M10
37 N·m (27 lb ft)
M12
64 N·m (47 lb ft)
M16
M20
M24
158 N·m (116 lb
ft)
319 N·m (235 lb
ft)
551 N·m (410 lb
ft)
2.9 N·m (26 lb
in)
5.9 N·m (52 lb
in)
10 N·m (89 lb
in)
25 N·m (217 lb
in)
49 N·m (36 lb
ft)
85 N·m (63 lb
ft)
210 N·m (155
lb ft)
425 N·m (313
lb ft)
735 N·m (500
lb ft)
CLASS 10.9 BOLT and
CLASS 10 NUT
PLATED
UNPLATED
W/ZnCr
3.2 N·m (28 lb 4.2 N·m (37 lb
in)
in)
6.4 N·m (57 lb 8.5 N·m (75 lb
in)
in)
11 N·m (96 lb 15 N·m (128 lb
in)
in)
26 N·m (234 lb 35 N·m (311 lb
in)
in)
70 N·m (51 lb
52 N·m (38 lb ft)
ft)
121 N·m (90 lb
91 N·m (67 lb ft)
ft)
225 N·m (166 lb 301 N·m (222
ft)
lb ft)
440 N·m (325 lb 587 N·m (433
ft)
lb ft)
762 N·m (560 lb 1016 N·m (750
ft)
lb ft)
LOCKNUT
CL.8
W/CL8.8
BOLT
2 N·m (18 lb in)
4 N·m (36 lb in)
6.8 N·m (60 lb
in)
17 N·m (151 lb
in)
33 N·m (25 lb
ft)
58 N·m (43 lb
ft)
143 N·m (106 lb
ft)
290 N·m (214 lb
ft)
501 N·m (370 lb
ft)
LOCKNUT
CL.10
W/CL10.9
BOLT
2.9 N·m (26 lb
in)
5.8 N·m (51 lb
in)
10 N·m (89 lb
in)
24 N·m (212 lb
in)
48 N·m (35 lb
ft)
83 N·m (61 lb
ft)
205 N·m (151 lb
ft)
400 N·m (295 lb
ft)
693 N·m (510 lb
ft)
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
47487696 17/01/2013
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INTRODUCTION
METRIC FLANGED HARDWARE
NOM.
SIZE
CLASS 8.8 BOLT and
CLASS 8 NUT
PLATED
W/ZnCr
UNPLATED
M4
M5
M6
M8
2.4 N·m (21 lb
in)
4.9 N·m (43 lb
in)
8.3 N·m (73 lb
in)
20 N·m (179 lb
in)
M10
40 N·m (30 lb ft)
M12
70 N·m (52 lb ft)
M16
M20
M24
174 N·m (128 lb
ft)
350 N·m (259 lb
ft)
607 N·m (447 lb
ft)
3.2 N·m (28 lb
in)
6.5 N·m (58 lb
in)
11 N·m (96 lb
in)
27 N·m (240 lb
in)
54 N·m (40 lb
ft)
93 N·m (69 lb
ft)
231 N·m (171
lb ft)
467 N·m (345
lb ft)
809 N·m (597
lb ft)
CLASS 10.9 BOLT and
CLASS 10 NUT
UNPLATED
LOCKNUT
CL.8
W/CL8.8
BOLT
LOCKNUT
CL.10
W/CL10.9
BOLT
2.2 N·m (19 lb
in)
4.4 N·m (39 lb
in)
7.5 N·m (66 lb
in)
18 N·m (163 lb
in)
3.1 N·m (27 lb
in)
6.4 N·m (57 lb
in)
11 N·m (96 lb
in)
27 N·m (240 lb
in)
PLATED
W/ZnCr
3.5 N·m (31 lb 4.6 N·m (41 lb
in)
in)
7.0 N·m (62 lb 9.4 N·m (83 lb
in)
in)
12 N·m (105 lb 16 N·m (141 lb
in)
in)
29 N·m (257 lb 39 N·m (343 lb
in)
in)
77 N·m (56 lb
57 N·m (42 lb ft)
ft)
100 N·m (74 lb 134 N·m (98 lb
ft)
ft)
248 N·m (183 lb 331 N·m (244
ft)
lb ft)
484 N·m (357 lb 645 N·m (476
ft)
lb ft)
838 N·m (618 lb 1118 N·m (824
ft)
lb ft)
37 N·m (27 lb ft) 53 N·m (39 lb ft)
63 N·m (47 lb ft) 91 N·m (67 lb ft)
158 N·m (116 lb
ft)
318 N·m (235 lb
ft)
552 N·m (407 lb
ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes
5.6 and up
1. Manufacturer's Identification
2. Property Class
20083680
1
20083681
2
Metric Hex nuts and locknuts, classes 05 and
up
1. Manufacturer's Identification
2. Property Class
3. Clock Marking of Property Class and Manufacturer's
Identification (Optional), i.e. marks 60 ° apart indicate
Class 10 properties, and marks 120 ° apart indicate
Class 8.
47487696 17/01/2013
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226 N·m (167 lb
ft)
440 N·m (325 lb
ft)
INTRODUCTION
INCH NON-FLANGED HARDWARE
NOMINAL
SIZE
SAE GRADE 5 BOLT
and NUT
UNPLATED
or
PLATED
SILVER
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
8 N·m (71 lb
in)
17 N·m (150
lb in)
30 N·m (22 lb
ft)
48 N·m (36 lb
ft)
74 N·m (54 lb
ft)
107 N·m (79
lb ft)
147 N·m (108
lb ft)
261 N·m (193
lb ft)
420 N·m (310
lb ft)
630 N·m (465
lb ft)
SAE GRADE 8 BOLT
and NUT
UNPLATED
PLATED
W/ZnCr
or PLATED
GOLD
SILVER
11 N·m (97 lb
in)
23 N·m (204
lb in)
40 N·m (30
lb ft)
65 N·m (48
lb ft)
98 N·m (73
lb ft)
142 N·m (105
lb ft)
196 N·m (145
lb ft)
348 N·m (257
lb ft)
561 N·m (413
lb ft)
841 N·m (620
lb ft)
12 N·m (106
lb in)
24 N·m (212
lb in)
43 N·m (31 lb
ft)
68 N·m (50 lb
ft)
104 N·m (77
lb ft)
150 N·m (111
lb ft)
208 N·m (153
lb ft)
369 N·m (272
lb ft)
594 N·m (438
lb ft)
890 N·m (656
lb ft)
LOCKNUT
GrB W/ Gr5
BOLT
LOCKNUT
GrC W/ Gr8
BOLT
PLATED
W/ZnCr
GOLD
16 N·m (142
lb in)
32 N·m (283
lb in)
57 N·m (42 lb
ft)
91 N·m (67 lb
ft)
139 N·m (103
lb ft)
201 N·m (148
lb ft)
277 N·m (204
lb ft)
491 N·m (362
lb ft)
791 N·m (584
lb ft)
1187 N·m
(875 lb ft)
12.2 N·m (109 lb
in)
17.5 N·m (155 lb 25 N·m (220 lb
in)
in)
8.5 N·m (75 lb in)
31 N·m (23 lb ft) 44 N·m (33 lb ft)
50 N·m (37 lb ft) 71 N·m (53 lb ft)
76 N·m (56 lb ft) 108 N·m (80 lb ft)
156 N·m (115 lb
ft)
153 N·m (113 lb 215 N·m (159 lb
ft)
ft)
271 N·m (200 lb 383 N·m (282 lb
ft)
ft)
437 N·m (323 lb 617 N·m (455 lb
ft)
ft)
654 N·m (483 lb 924 N·m (681 lb
ft)
ft)
111 N·m (82 lb ft)
NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in
through 1 in hardware torque specifications are shown in pound-feet.
47487696 17/01/2013
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INTRODUCTION
INCH FLANGED HARDWARE
NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and
INAL
NUT
NUT
SIZE
UNPLATED
PLATED
UNPLATED
PLATED
or PLATED
W/ZnCr
or PLATED
W/ZnCr
SILVER
GOLD
SILVER
GOLD
1/4
9 N·m (80 lb in)
5/16
19 N·m (168 lb
in)
3/8
33 N·m (25 lb ft)
7/16
53 N·m (39 lb ft)
1/2
81 N·m (60 lb ft)
9/16
5/8
3/4
7/8
1
117 N·m (86 lb
ft)
162 N·m (119 lb
ft)
287 N·m (212 lb
ft)
462 N·m (341 lb
ft)
693 N·m (512 lb
ft)
12 N·m (106 lb
in)
25 N·m (221 lb
in)
44 N·m (33 lb
ft)
71 N·m (52 lb
ft)
108 N·m (80 lb
ft)
156 N·m (115
lb ft)
216 N·m (159
lb ft)
383 N·m (282
lb ft)
617 N·m (455
lb ft)
925 N·m (682
lb ft)
13 N·m (115 lb
in)
26 N·m (230 lb
in)
47 N·m (35 lb
ft)
75 N·m (55 lb
ft)
115 N·m (85 lb
ft)
165 N·m (122
lb ft)
228 N·m (168
lb ft)
405 N·m (299
lb ft)
653 N·m (482
lb ft)
979 N·m (722
lb ft)
IDENTIFICATION
17 N·m (150 lb
in)
35 N·m (310 lb
in)
63 N·m (46 lb
ft)
100 N·m (74 lb
ft)
153 N·m (113
lb ft)
221 N·m (163
lb ft)
304 N·m (225
lb ft)
541 N·m (399
lb ft)
871 N·m (642
lb ft)
1305 N·m (963
lb ft)
LOCKNUT
GrF W/ Gr5
BOLT
8 N·m (71 lb in)
17 N·m (150 lb
in)
48 N·m (35 lb ft) 68 N·m (50 lb ft)
74 N·m (55 lb ft)
106 N·m (78 lb ft)
147 N·m (108 lb
ft)
261 N·m (193 lb
ft)
421 N·m (311 lb
ft)
631 N·m (465 lb
ft)
Grade Marking Examples
3
SAE Grade
Grade 2 - No Marks
Grade 5 - Three
Marks
Grade 8 - Five Marks
Identification
4 Grade 2 Nut - No Marks
5 Grade 5 Nut - Marks
120 ° Apart
6 Grade 8 Nut - Marks 60
° Apart
20107570
3
20090268
4
Inch Lock Nuts, All Metal (Three optional
methods)
Grade Identification
Grad- Corner Marking Flats Marking
Method (2)
e
Method (1)
Grad- No Notches
eA
Grad- One
eB
Circumferential
Notch
Grad- Two
Circumferential
eC
Notches
No Mark
Clock
Marking
Method (3)
No Marks
Letter B
Three Marks
Letter C
Six Marks
47487696 17/01/2013
20
12 N·m (106 lb
in)
24 N·m (212 lb
in)
30 N·m (22 lb ft) 43 N·m (32 lb ft)
Inch Bolts and free-spinning nuts
1
2
LOCKNUT
GrG W/ Gr8
BOLT
104 N·m (77 lb
ft)
157 N·m (116 lb
ft)
207 N·m (153 lb
ft)
369 N·m (272 lb
ft)
594 N·m (438 lb
ft)
890 N·m (656 lb
ft)
INTRODUCTION
Torque - Standard torque data for hydraulics
INSTALLATION OF ADJUSTABLE FITTINGS
IN STRAIGHT THREAD O RING BOSSES
1. Lubricate the O-ring by coating it with a light oil or
petroleum. Install the O-ring in the groove adjacent
to the metal backup washer which is assembled at the
extreme end of the groove (4).
2. Install the fitting into the SAE straight thread boss until
the metal backup washer contacts the face of the boss
(5).
NOTE: Do not over tighten and distort the metal
backup washer.
23085659
1
3. Position the fitting by turning out (counterclockwise)
up to a maximum of one turn. Holding the pad of the
fitting with a wrench, tighten the locknut and washer
against the face of the boss (6).
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS
TUBE NUTS FOR 37° FLARED FITTINGS
SIZE
TUBING OD
THREAD
SIZE
TORQUE
O-RING BOSS PLUGS
ADJUSTABLE FITTING
LOCKNUTS, SWIVEL
JIC- 37° SEATS
TORQUE
4
5
6
8
10
12
14
16
20
24
32
6.4 mm (1/4 in)
7.9 mm (5/16 in)
9.5 mm (3/8 in)
12.7 mm (1/2 in)
15.9 mm (5/8 in)
19.1 mm (3/4 in)
22.2 mm (7/8 in)
25.4 mm (1 in)
31.8 mm (1-1/4 in)
38.1 mm (1-1/2 in)
50.8 mm (2 in)
7/16-20
1/2-20
9/16-18
3/4-16
7/8-14
1-1/16-12
1-3/16-12
1-5/16-12
1-5/8-12
1-7/8-12
2-1/2-12
12 - 16 N·m (9 - 12 lb ft)
16 - 20 N·m (12 - 15 lb ft)
29 - 33 N·m (21 - 24 lb ft)
47 - 54 N·m (35 - 40 lb ft)
72 - 79 N·m (53 - 58 lb ft)
104 - 111 N·m (77 - 82 lb ft)
122 - 136 N·m (90 - 100 lb ft)
149 - 163 N·m (110 - 120 lb ft)
190 - 204 N·m (140 - 150 lb ft)
217 - 237 N·m (160 - 175 lb ft)
305 - 325 N·m (225 - 240 lb ft)
8 - 14 N·m (6 - 10 lb ft)
14 - 20 N·m (10 - 15 lb ft)
20 - 27 N·m (15 - 20 lb ft)
34 - 41 N·m (25 - 30 lb ft)
47 - 54 N·m (35 - 40 lb ft)
81 - 95 N·m (60 - 70 lb ft)
95 - 109 N·m (70 - 80 lb ft)
108 - 122 N·m (80 - 90 lb ft)
129 - 158 N·m (95 - 115 lb ft)
163 - 190 N·m (120 - 140 lb ft)
339 - 407 N·m (250 - 300 lb ft)
These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm
(0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually.
Before installing and torquing 37 ° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite
cleaner and apply hydraulic sealant LOCTITE® 569 to the 37 ° flare and the threads.
Install fitting and torque to specified torque, loosen fitting and retorque to specifications.
47487696 17/01/2013
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INTRODUCTION
PIPE THREAD FITTING TORQUE
PIPE THREAD FITTING
Before installing and tightening pipe fittings, clean the
threads with a clean solvent or Loctite cleaner and apply
sealant LOCTITE® 567 PST PIPE SEALANT for all fittings
including stainless steel or LOCTITE® 565 PST for most
metal fittings. For high filtration/zero contamination systems use LOCTITE® 545.
Torque (Maximum)
13 N·m (10 lb ft)
16 N·m (12 lb ft)
22 N·m (16 lb ft)
41 N·m (30 lb ft)
54 N·m (40 lb ft)
Thread Size
1/8-27
1/4-18
3/8-18
1/2-14
3/4-14
INSTALLATION OF ORFS (O-RING FLAT
FACED) FITTINGS
When installing ORFS fittings thoroughly clean both flat
surfaces of the fittings (1) and lubricate the O-ring (2) with
light oil. Make sure both surfaces are aligned properly.
Torque the fitting to specified torque listed throughout the
repair manual.
NOTICE: If the fitting surfaces are not properly cleaned,
the O-ring will not seal properly. If the fitting surfaces are
not properly aligned, the fittings may be damaged and will
not seal properly.
NOTICE: Always use genuine factory replacement oils
and filters to ensure proper lubrication and filtration of engine and hydraulic system oils.
The use of proper oils, grease, and keeping the hydraulic
system clean will extend machine and component life.
47487696 17/01/2013
22
50011183
2
INTRODUCTION
Basic instructions - Shop and assembly
SHIMMING
For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up
the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value
indicated on each shim.
ROTATING SHAFT SEALS
For correct rotating shaft seal installation, proceed as follows:
• before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.
• thoroughly clean the shaft and check that the working surface on the shaft is not damaged.
• position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction
and position the grooves so that they will deviate the fluid towards the inner side of the seal.
• coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip
and the dust lip on double lip seals with grease.
• insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a
hammer or mallet.
• whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes contact
with the thrust element, if required.
• to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.
O-RING SEALS
Lubricate the O-RING seals before inserting them in the seats, this will prevent them from overturning and twisting,
which would jeopardise sealing efficiency.
SEALING COMPOUNDS
Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or
LOCTITE® RTV 598 or LOCTITE® INSTANT GASKET 587 BLUE. Before applying the sealing compound, prepare the
surfaces as directed on product container or as follows:
• remove any incrustations using a metal brush.
• thoroughly de-grease the surfaces using a locally approved cleaning agent such as safety solvent or brake parts
cleaner.
SPARE PARTS
Only use "CNH Original Parts" or " NEW HOLLAND AGRICULTURE 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
AGRICULTURE Parts" can offer this guarantee.
When ordering spare parts, always provide the following information:
• machine model (commercial name) and serial number.
• part number of the ordered part, which can be found in the "Microfiches" or the "Service Parts Catalogue", used for
order processing.
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INTRODUCTION
PROTECTING THE ELECTRONIC/ ELECTRICAL SYSTEMS DURING CHARGING OR WELDING
WARNING
Battery acid causes burns. Batteries contain sulfuric acid.
Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush
with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large
quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.
Failure to comply could result in death or serious injury.
W0111A
To avoid damage to the electronic/electrical systems, always observe the following:
1. Never make or break any of the charging circuit connections, including the battery connections, when the engine
is running.
2. Never short any of the charging components to ground.
3. Always disconnect the ground cable from the battery before arc welding on the windrower or on any header attached to the windrower.
• position the welder ground clamp as close to the welding area as possible.
• if welding in close proximity to a computer module, then the module should be removed from the windrower.
• never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding
is in progress.
4. Always disconnect the negative cable from the battery when charging the battery in the windrower with a battery
charger.
NOTICE: If welding must be performed on the unit, either the windrower or the header (if it is attached), the battery
ground cable must be disconnected from the windrower battery. The electronic monitoring system and charging system will be damaged if this is not done.
Remove the battery ground cable. Reconnect the cable when welding is completed.
TOOLS
The tools that NEW HOLLAND AGRICULTURE suggests and illustrate in this manual have been:
• specifically researched and designed for use with NEW HOLLAND AGRICULTURE machines.
• essential for reliable repair operations.
• accurately built and rigorously tested so as to offer efficient and long-lasting operation.
By using these tools, repair personnel will benefit from:
• operating in optimal technical conditions.
• obtaining the best results.
• saving time and effort.
• working in safe conditions.
NOTE: The terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from
the rear, facing in the direction of travel of the machine during operation.
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INTRODUCTION
Basic instructions - Hydraulic contamination
[YCG667001-], [YCG667001-]
Contamination in the hydraulic system is a major cause of the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil.
Contamination can enter the hydraulic system in several ways:
• When you drain the oil or disconnect any line
• When you disassemble a component
• From normal wear of the hydraulic components
• From damaged seals or worn seals
• From a damaged component in the hydraulic system
All hydraulic systems operate with some contamination. The design of the components in this hydraulic system permits efficient operation with a small amount of contamination. An increase in this amount of contamination can cause
problems in the hydraulic system.
The following list includes some of these problems:
• Cylinder rod seals that leak
• Control valve spools that do not return to neutral
• Movement of control valve spools is difficult
• Hydraulic oil that becomes too hot
• Pump gears, housing, and other parts that wear rapidly
• Relief valves or check valves held open by dirt
• Quick failure of components that have been repaired
• Slow cycle times are slow. The machine does not have enough power.
If your machine has any of these problems, check the hydraulic oil for contamination.
There are two types of contamination: microscopic and visible.
Microscopic contamination occurs when very fine particles of foreign material are suspended in the hydraulic oil.
These particles are too small to see or feel. Microscopic contamination can be found by identification of the following
problems or by testing in a laboratory.
Examples of problems caused by microscopic contamination:
• Cylinder rod seals that leak
• Control valve spools that do not return to neutral
• The hydraulic system has a high operating temperature
Visible contamination is foreign material that can be found by sight, touch, or odor. Visible contamination can cause
a sudden failure of components.
Examples of problems caused by visible contamination:
• Particles of metal or dirt in the oil
• Air in the oil
• Dark or thick oil
• Oil with an odor of burned oil
• Water in the oil
If you find contamination, use a portable filter to clean the hydraulic system.
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INTRODUCTION
General specification
[YCG667001-], [YCG667001-]
Engine
Model source
Bore
Stroke
Displacement
Compression
Firing order
Power
Rated RPM
Peak torque
Idle speed
Max. no load speed
H8060
6-cyl diesel turbocharged w/ charge
air cooler
104 mm (4.1 in)
132 mm (5.2 in)
6.7 l (409 in³)
17.5:1
153624
142 kW (190 Hp)
2200 RPM
830 N·m (612 lb ft) @ 1600 RPM
900 RPM
2250 RPM
H8080
6-cyl diesel turbocharged w/ charge
air cooler
104 mm (4.1 in)
132 mm (5.2 in)
6.7 l (409 in³)
17.5:1
153624
168 kW (225 Hp)
2200 RPM
961 N·m (709 lb ft) @ 1600 RPM
900 RPM
2250 RPM
H8060
89.6 kPa (13 psi)
7 blade / 711 mm (28 in)
H8080
89.6 kPa (13 psi)
7 blade / 711 mm (28 in)
H8060
Bosch Common Rail CP 3.3
H8080
Bosch Common Rail CP 3.3
H8060
12 V
150 A
(2), GP31 650 CCA
Iskra 12 V 4.2 kW (5.6 Hp)
H8080
12 V
150 A
(2), GP31 650 CCA
Iskra 12 V 4.2 kW (5.6 Hp)
Cooling system
Radiator cap pressure
Fan- Number of blades/diameter
Fuel system
Injector pump
Electrical system
Voltage
Alternator output
Batteries - 12 V
Starter motor
Rear axle
Type
Adjustment range (3 positions)
H8060 / H8080
Air suspension optional
2286 mm - 2667 mm - 3048 mm ( 90 in - 105 in - 120 in)
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INTRODUCTION
Tires
Front
Front
Front
Front
Front
Front
Front
option
option
option
option
option
option
option
H8060 / H8080
480/80R26 149 R3 turf radial
18.4 x 26 cleat R4 12 ply
18.4R26 cleat R1 radial
21L x 28 cleat R4 14 ply
16.9 x 28 cleat R4 12 ply
580/70R26 149 R3 turf radial
600/65R28 154 R1W radial
14L x 16.1 ribbed 8 ply
A
B
C
D
E
F
G
Rear tires
Maximum speed - Minimum factory setting
H8060 / H8080
Option A
Low
High
0 - 18.2 km/h (0 - 11.3 mph)
0 - 27.0 km/h (0 - 16.8 mph)
Option B
Low
High
0 - 17.7 km/h (0 - 11.0 mph)
0 - 26.4 km/h (0 - 16.4 mph)
Option C
Low
High
0 - 18.2 km/h (0 - 11.3 mph)
0 - 27.0 km/h (0 - 16.8 mph)
Option D
Low
High
0 - 18.3 km/h (0 - 11.4 mph)
0 - 27.4 km/h (0 - 17.0 mph)
Option E
Low
High
0 - 17.5 km/h (0 - 10.9 mph)
0 - 26.2 km/h (0 - 16.3 mph)
Option F
Low
High
0 - 18.8 km/h (0 - 11.7 mph)
0 - 28.0 km/h (0 - 17.4 mph)
Option G
Low
High
0 - 18.7 km/h (0 - 11.6 mph)
0 - 27.8 km/h (0 - 17.3 mph)
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INTRODUCTION
Dimensions
Length
H8060 / H8080
5760 mm (226.8 in)
5213 mm (205 in)
3494 mm (137.6 in)
With lift arms
Without lift arms
Wheel base
Height
Option
Option
Option
Option
Option
Option
Option
H8060 / H8080
3378 mm (133 in)
3387 mm (133.4 in)
3388 mm (133.4 in)
3421 mm (134.7 in)
3388 mm (133.4 in)
3396 mm (133.7 in)
3411 mm (134.3 in)
A
B
C
D
E
F
G
Rear axle clearance
H8060 / H8080
908 mm (35.7 in)
986 mm (38.8 in)
Low
High
Width
Option
Option
Option
Option
Option
Option
Option
H8060 / H8080
3748 mm (147.6 in)
3740 mm (147.3 in)
3755 mm (147.9 in)
3882 mm (152.8 in)
3641 mm (143.3 in)
3891 mm (153.2 in)
3965 mm (156.1 in)
3575 mm (140.7 in)
A
B
C
D
E
F
G
Front wheel hubs
Weight
H8060 / H8080
5212 kg (11490 lb)
+95 kg (210 lb)
+69 kg (158 lb)
389 kg (858 lb)
With option D tires and full fuel tank
Suspended rear axle
Draper ready
Fuel (Full tank)
47487696 17/01/2013
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INTRODUCTION
Capacities
[YCG667001-], [YCG667001-]
Capacities
Engine oil
Flywheel gearbox
Cooling system
Fuel
Hydraulic system reservoir
Final drives
A/C system (R134a)
15 l (16 US qt) with filter
1.52 l (1.6 US qt)
31.4 l (8.3 US gal)
454 l (120 US gal)
54.9 l (14.5 US gal)
1.75 l (1.8 US qt)
2.2 kg (4.75 lb)
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INTRODUCTION
General specification - Biodiesel Fuels
Fatty Acid Methyl Ester Biodiesel (Biodiesel Fuel) consists of a family of fuels derived from vegetable oils treated with
methyl esters.
NOTICE: Biodiesel Fuel blends are approved for your engine only if they comply with EN14214 Specification Standards or ASTM D6751.
NOTICE: It is imperative that you check which blend is approved for your engine with your NEW HOLLAND AGRICULTURE dealer. Be aware that the use of Biodiesel Fuel that does not comply with the Standards mentioned above
could lead to severe damage to the engine and fuel system of your machine. The use of fuels that are not approved
may void NEW HOLLAND AGRICULTURE Warranty coverage.
Biodiesel Fuel Usage Conditions
NOTICE: The Biodiesel Fuel must meet the fuel Specification mentioned above.
Biodiesel Fuel must be purchased from a trusted supplier that understands the product and maintains good fuel quality. Biodiesel Fuel must be pre-blended by the supplier. Mixing Biodiesel Fuels on-site can result incorrect mixture
that can lead to problems with both engine and fuel system.
Engine performance is affected by the use of Biodiesel Fuel. There may be up to 12 % reduction in power or torque
depending on the blend used.
NOTICE: DO NOT modify the engine and/or injection pump settings to recover the reduced performance.
The reduced power must be accepted if using any Biodiesel Fuel blend.
Some modification may be required to allow your engine to run Biodiesel Fuel. Consult you dealer for complete
information on these modifications.
Biodiesel Fuel has a higher cloud point than Diesel Fuel.
NOTICE: The use of high Biodiesel Fuel blends are not recommended in cold weather conditions.
With Biodiesel Fuels, it may be necessary to change the engine oil, engine oil filter and fuel filter elements more
frequently than with Diesel Fuels. Biodiesel Fuel can remove rust and particles from the inside of on-site fuel storage
tanks that would normally adhere to the sides of the tank. Like particle deposits that commonly occur with Diesel
Fuel, these particles can become trapped by the machine fuel filters, causing blockage and shortening filter life. In
cold weather, this is more likely to happen. Consult your NEW HOLLAND AGRICULTURE dealer for information on
cold weather operation and proper maintenance intervals when using any Biodiesel Fuel blend.
When handling Biodiesel Fuel, care must be taken not to allow water into the fuel supply. Biodiesel Fuel will actually
attract moisture from the atmosphere.
Fuel tanks must be kept as full as possible to limit the amount of air and water vapors in them. It may be necessary
to drain the fuel filter water tap more frequently.
Potential oxidation and stability could be a problem with the fuel stored in the machine.
NOTICE: Machines must not be stored for more than three months with Biodiesel Fuel blends in the fuel system.
If long storage periods are necessary, the engine must run on Diesel Fuel for 20 hours to flush the Biodiesel Fuel out
of the engine fuel system prior to storage.
NOTICE: Biodiesel Fuel must not be stored in on-site storage tanks for more than three months.
Any spillage of Biodiesel Fuel must be cleaned up immediately before it can cause damage to the environment and
the paint finish of the machine.
Before using Biodiesel Fuel blends you should consult with your dealer to receive full information about the approved
blend for your machine and any detailed conditions of its usage.
NOTICE: Be aware that not fulfilling the requirements and conditions of Biodiesel Fuel usage will void your machine’s
NEW HOLLAND AGRICULTURE Warranty coverage.
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INTRODUCTION
Product identification
[YCG667001-], [YCG667001-]
The identification number of the windrower and engine are required when ordering service parts. Record these numbers in the front of this manual. These numbers may also be required to identify a stolen windrower.
Windrower identification number
The windrower identification plate (1) is located on the left
side of the frame, next to the platform steps (2). The identification plate includes the model number and the PIN.
93100219
1
87757522
2
76075543
3
Engine serial number
The engine specifications are on an engine-mounted plate
(1) located on the left side of the engine oil pan (2).
47487696 17/01/2013
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INTRODUCTION
Product overview - Machine orientation
[YCG667001-], [YCG667001-]
To determine "left-hand" (LH) and "right-hand" (RH) stand at the rear of the machine and face the normal direction of
travel as indicated by arrow in figure.
NHIL12WR00341FA
1
1. Front of the machine
3. Rear of the machine
2. Right-hand side of the machine
4. Left-hand side of the machine
47487696 17/01/2013
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CONSUMABLES INDEX
Consumable
Loctite®
Loctite®
Sealant
Loctite®
Loctite®
Loctite®
Loctite®
Blue
Reference
PAGE
569
567 PST Pipe
Torque - Standard torque data for hydraulics
Torque - Standard torque data for hydraulics
21
22
565 PST
545
RTV 598
Instant Gasket 587
Torque - Standard torque data for hydraulics
Torque - Standard torque data for hydraulics
Basic instructions - Shop and assembly
Basic instructions - Shop and assembly
22
22
23
23
47487696 17/01/2013
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47487696 17/01/2013
34
SERVICE MANUAL
Engine
H8060
H8080
47487696-10 17/01/2013
10
Contents
Engine - 10
[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
H8060 , H8080
[10.202] Air cleaners and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2
H8060 , H8080
[10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
H8060 , H8080
[10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
H8060 , H8080
[10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
H8060 , H8080
[10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
H8060 , H8080
[10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
H8060 , H8080
47487696-10 17/01/2013
10
CONSUMABLES INDEX
Consumable
Loctite® 598 Ultra Black
NEW HOLLAND Ambra
Hypoide 90
NEW HOLLAND AMBRA
HYPOIDE SSL GEAR OIL
Reference
PAGE
Engine - Install
Engine - Install
10.1 / 14
10.1 / 15
Engine - Install
10.1 / 15
47487696-10 17/01/2013
10
47487696-10 17/01/2013
10
Engine - 10
Engine and crankcase - 001
H8060
H8080
47487696-10.001 17/01/2013
10.1 [10.001] / 1
Contents
Engine - 10
Engine and crankcase - 001
TECHNICAL DATA
Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Engine
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Engine
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
[YCG667001-], [YCG667001-]
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
[YCG667001-], [YCG667001-]
DIAGNOSTIC
Engine
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
47487696-10.001 17/01/2013
10.1 [10.001] / 2
CONSUMABLES INDEX
Consumable
Loctite® 598 Ultra Black
NEW HOLLAND Ambra
Hypoide 90
NEW HOLLAND AMBRA
HYPOIDE SSL GEAR OIL
Reference
PAGE
Engine - Install
Engine - Install
10.1 / 14
10.1 / 15
Engine - Install
10.1 / 15
47487696-10.001 17/01/2013
10.1 [10.001] / 3
Engine - Engine and crankcase
Engine - General specification
Model
Cylinders
Aspiration
Bore
Stroke
Displacement
Compression
Firing order
Power
Rated RPM
Torque at Rated RPM
Torque Rise %
Peak Torque
Idle Speed
Max. No Load Speed
H8060
H8080
6
turbocharged w/ charge air cooler
104 mm (4.4 in)
132 mm (5.0 in)
6.7 L (456 cuin)
17.5 to 1
1–5–3–6–2–4
142 kW (190HP)
2200 RPM
636 N·m (469 ft-lb)
23%
830N·m (612 ft-lb) @ 1600 RPM
900 RPM
2250 RPM
6
turbocharged w/ charge air cooler
104 mm (4.4 in)
132 mm (5.0 in)
6.7 L (456 cuin)
17.5 to 1
1–5–3–6–2–4
142 kW (190HP)
2200 RPM
768 N·m (566 ft-lb)
25%
961N·m (709 ft-lb) @ 1600 RPM
900 RPM
2250 RPM
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Engine - Engine and crankcase
Engine - Overview
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The NEF Tier III engine is a 6–cylinder turbocharged and after cooled unit, having a bore of 104 mm (4.4 in)
and a stroke of 132 mm (5.0 in) which generates a displacement of 410 in³.
The engine uses a electronically controlled hi-pressure injection pump and has been designed to meet
current emission regulations and must only be serviced by an authorized service agent.
All engines fearure cross flow cylinder heads, with the inlet and exhaust manifolds on opposite sides of
the cylinder head. The fuel and air combustion process, takes place in the specially designed bowl in the
crown of the pistons.
NOTE: The FRONT of the engine is the water pump end. The REAR of the engine is the flywheel end. In this section,
right and left correspond to the above when standing at the rear of the engine looking at the flywheel end with the
water pump end away from you.
Cylinder block assembly
The cylinder block is an alloy cast iron with deep cylinder skirts, and water jackets for cooling the cylinders. The
cylinder bores are machined integral with the cylinder block, during the manufacturing process.
Cylinders are in line and vertical and numbered 1 to 6 from the front (fan end) to the rear of the engine. They can be
bored oversize for the fitment of sleeves, which are available in service.
In the following procedures and illustrations the engine is shown removed from the vehicle however there are certain
operations that can be performed with the engine installed. Where it is necessary to remove the engine use a suitable
hoist or overhead gantry and standard engineering procedures. Removal of the engine is described in Chapter 1 of
Section 10 of this manual. Dismantle the engine following conventional techniques and by referring to the appropriate
overhaul sections of this chapter. Always refer to the specification section as necessary.
NOTE: Where it is necessary to remove additional items to gain access to the components on the engine refer to
Engine Removal.
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Engine - Engine and crankcase
NOTICE: All gaskets, seals, and O-rings must be replaced during reassembly. Where new sealant is to be applied
refer to Engine Specifications.
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Engine - Engine and crankcase
Engine - Remove
[YCG667001-], [YCG667001-]
1.
2.
Remove bolt (1) on starter to disconnect ground cable (2). Remove batteries negative ground cable (3)
from engine.
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Remove battery post nut and disconnect positive battery cable (1). Remove protective cap and disconnect all cables from starter solenoid (2). Disconnect
cable and two wires (3) from alternator (4). Remove
complete wire harness from engine block.
3.
Drain coolant from radiator and engine by opening
valve (1). Catch fluid from drain hose and save for
recycling. Remove the radiator cap to speed up the
draining, using caution if the system is hot.
4.
Disconnect drain hose (2).
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Engine - Engine and crankcase
5.
Loosen pipe clamp (1) and remove exhaust stack
(2). Remove pipe clamp (3) clamp (4) and remove
pre-cleaner assembly (5).
6.
Using a helper, detach four gas springs (1) from engine area side doors by removing four flange nuts
and lock washers.
7.
Remove side doors by removing one bolt (2) and
loosening one (3) at each of twelve pivot clips (4).
8.
Remove four carriage bolts, lock washers and flange
nuts (5) that secure the front of the hood.
9.
10.
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Remove four flange bolts (1) that secure the rear of
the hood to the radiator support frame.
Disconnect restriction indicator switch (1).
NOTE: Restriction switch is located behind outlet tube (2).
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