SECTIONK-CROPPROCESSING56
Thefollowingpagesarethecollationofthecontentspagesfromeachsectionand chapteroftheBW28,BW38Repairmanual.CompleteRepairpart#87693295.
ThesectionsusedthroughoutallNewHollandproductRepairmanualsmaynotbe usedforeachproduct.EachRepairmanualwillbemadeupofoneorseveralbooks. EachbookwillbelabeledastowhichsectionsareintheoverallRepairmanualand whichsectionsareineachbook.
ThesectionslistedabovearethesectionsutilizedfortheBW28,BW38BaleWagons.
87693303 7/07 1stPrinting © 2007CNHAmericaLLC PrintedInU.S.A. BW28,BW38 REPAIRMANUAL COMPLETECONTENTS
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................................. SECTIONC-POWERTRAIN32 .........................................
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SECTIONA-DISTRIBUTIONSYSTEMS2
SECTIONB-POWERPRODUCTION23
SECTIOND-TRAVELLING33
SECTIONE-BODYANDSTRUCTURE45
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2
BOOK1-87693296 PrimaryHydraulicPowerSystem-10 CONTENTS SectionDescription Page Introduction 7 Filtration 7 ............................................................... ComponentLocation8 ReadingDiagramSymbols9 ...................................................... SystemDiagram13 PistonPumpManifold15 ..................................................... GearPumpManifold16 Closed-centerSystem(MainPistonPump)17 ...................................... FunctionsControlled17 LoadSensing17 Specifications17 Pump 17 ReliefValves17 SystemOilFlow17 ClosedCenter18 ............................................................ SystemDiagram18 SystemOperation19 ......................................................... Pump 19 CoolingFan19 .......................................................... Fan-reversing19 FirstTable20 ............................................................ SecondTable21 TieSpikes21 ............................................................ LoadRack21 RollingRack22 .......................................................... Push-offFeet22 PistonPumpValveManifold(PPM)23 ............................................. Introduction 23 Components23 ServiceParts23 ValveIdentificationCodes24 ComponentIdentificationandLocation25 .......................................
DISTRIBUTIONSYSTEMS-A
DISTRIBUTIONSYSTEMS-A
3
BOOK1-87693296 PrimaryHydraulicPowerSystem-10(Continued) CONTENTS SectionDescription Page Left-hand(LH)View25 FrontView26 ............................................................ Right-hand(RH)View27 RearView28 ............................................................ PlanView29 BottomView30 .......................................................... ComponentInformation31 CircuitDiagrams32 .......................................................... Load-holdingManifoldValve53 Introduction 53 Components53 ServiceParts53 IdentificationCodes53 ComponentIdentificationAndLocation54 ComponentInformation54 .................................................... Fan-reversingValve55 Introduction 55 .............................................................. Components55 ServiceParts55 ............................................................. IdentificationCodes55 ComponentIdentificationAndLocation56 ....................................... ComponentInformation56 Open-CenterSystem(DoubleGearPump)57 ...................................... FunctionsControlled57 Specifications57 ............................................................ Pump 57 Motors 57 ............................................................... ReliefValves57 Back-pressureValve57 SystemOilFlow57 SystemOperation58
DISTRIBUTIONSYSTEMS-A
4
BOOK1-87693296 PrimaryHydraulicPowerSystem-10(Continued) CONTENTS SectionDescription Page MotorCircuit58 Steering/BrakeCircuit59 .................................................. GearPumpValveManifold(GPM)60 Introduction 60 .............................................................. Components60 ServiceParts60 ............................................................. IdentificationCodes61 ComponentIdentificationandLocation62 ....................................... Left-hand(LH)View62 FrontView63 Right-hand(RH)View64 RearView65 PlanView66 ComponentInformation67 CircuitDiagrams68 .......................................................... SpoolValve 74 Introduction 74 .............................................................. SolenoidCoil76 Replacement76 ......................................................... Removal77 ElectricalSchematic-MainManifold80 ..................................... ElectricalSchematic-Hydraulics81 Installation82 ............................................................ ValveAssembly83 Removal83 ............................................................. Installation84 Valve 85 .................................................................... Disassemble85 Assemble86 CartridgeValves(Solenoid-operated)88 Introduction 88
DISTRIBUTIONSYSTEMS-A
PrimaryHydraulicPowerSystem-10(Continued) CONTENTS
SectionDescription
Two-wayTwo-positionPoppetValves89
Three-wayTwo-positionSpoolValves92
ElectricalSchematic-MainManifold96 .....................................
ElectricalSchematic-Hydraulics97
ElectricalSchematic-FanRelay98
Brake-pressureValve(BPV)105
Load-sensingShuttleValve(LSSV)106
FanSensingRelief(FSRV)ñ76bar(1100psi)110 ...........................
RollingRackRelief(RRRV)ñ76bar(1100psi)110
SecondTableRelief(STRV)ñ145bar(2100psi)110 .........................
Fan-ReversingReliefñ110bar(1600psi)110
MotorRelief(MRV)ñ158bar(2300psi)110 .................................
PowerSteeringRelief(PSRV)ñ158bar(2300psi)110
5
BOOK1-87693296
Page ValveStylesandFunctions89
.................................... NormallyClosed89 NormallyOpen91 ........................................................
SolenoidCoil93 ............................................................. Removal93
Cartridge 102 Replacement102
Installation100
CartridgeValves(Pressure-orPilot-operated)104 Introduction104 .............................................................
..................................... Load-holdingValve107 Non-solenoidCartridgeValve108 .............................................. Replacement108 Adjustment108 .......................................................... ReliefValves109
Adjustment111 FlowDividers112 CheckValves113
6
BOOK1-87693296 PrimaryHydraulicPowerSystem-10(Continued) CONTENTS SectionDescription Page Orifices 118 GearPump123 ............................................................. Removal123 RepairInformation123 .................................................... ToolsRequired123 Disassemble125 ......................................................... Inspection 129 General129 ............................................................. GearAssembly129 Inspection129 FrontplateandBackplate129 Inspection129 PumpBody129 Inspection129 Assemble130 ........................................................... Installation135 Start-upProcedure135 ................................................... PistonPump 136 HowLoadSensingWorks137 ................................................. RepairInformation151 RequiredStandardTools151 .............................................. SpecialTools151 Removal153 ............................................................ Disassemble154 FrontShaftBearing156 ...................................................... Removal156 Inspection156 ........................................................... Replacement157 Installation158 Compensator159 Disassemble159
DISTRIBUTIONSYSTEMS-A
DISTRIBUTIONSYSTEMS-A
7
BOOK1-87693296 PrimaryHydraulicPowerSystem-10(Continued) CONTENTS SectionDescription Page Inspection159 Assemble160 ........................................................... RotatingGroup161 Disassemble161 ......................................................... Inspection162 Assemble162 ........................................................... PistonPump163 Assemble163 ........................................................... ShaftBearingPreload167 Adjustment167 PintleBearingPreload168 Adjustment168 PistonPump170 Installation170 Start-upProcedure171 ................................................... Compensator172 Adjustment172 .......................................................... SystemTesting173 Pressure 173 ............................................................... Flow 174 PumpOutputTest175 ........................................................ Open-centerCircuit(GearPump)175 Closed-centerCircuit(PistonPump)176 .................................... CaseDrainFlow(PistonPump)179 Troubleshooting180 ............................................................. Open-centerSystem(GearPump)180 NoFunctionsWillOperate180 ............................................. AllFunctionsaretooSlow180 AllFunctionsaretooFast180 Closed-centerSystem(PistonPump)181 SystemNotDevelopingAdequatePressure181
DISTRIBUTIONSYSTEMS-A
8
BOOK1-87693296 PrimaryHydraulicPowerSystem-10(Continued) CONTENTS SectionDescription Page SystemNotDevelopingAdequateFlow182 HydraulicSystemOverheating182 ......................................... CoolingFanStopsBeforeAchievingFullOperatingSpeed183 Specifications 184 ............................................................... Pumps 184 ValveManifoldandComponents184 ........................................ FlowDividers184 MotorFlowDivider(MFD)185 ............................................. ReliefValves185 LoadRackValve185 Filters 185 Capacity185 Oil 185 HydraulicSystemCycleTimes186 LaborGuide 187 ................................................................ SpoolValve187 CartridgeValve187 ....................................................... ReliefValve187 FlowDivider187 ......................................................... CheckValve187 Orifice 187 .............................................................. LoadHoldingValve187 GearPump187 .......................................................... PistonPump188 OrbitMotors188 ......................................................... Cylinders188 Reservoir188 ............................................................ Testing 188
9 DISTRIBUTIONSYSTEMS-A BOOK2-87693297 ElectricalPowerSystem-30 CONTENTS SectionDescription Page GeneralElectrical8 DefinitionofTerms8 .......................................................... GroundSystem 10 Introduction 10 .............................................................. GroundPoints10 GroundPointLocations11 ..................................................... GroundH11 Ground112 ............................................................. Ground212 Ground313 Ground413 Ground1013 ElectricalSystemComponents14 ElectricalPanelLocations14 AccesstoRearElectricalPanel(NearEngine)14 ............................. JunctionBlock(W-01)14 JunctionBlock(W-01)Connections15 ...................................... AccesstoCabConsolePanel15 Fuses 15 ................................................................... FuseRemoval15 CircuitBreakers16 .......................................................... Relays 16 RelayOperation16 ....................................................... MiniRelays17 MicroRelays17 .......................................................... Fuses 18 CircuitBreakers18 ....................................................... Relays 18 Fuses 19 CircuitBreakers19 Relays 19 JunctionBox19 ..........................................................
DISTRIBUTIONSYSTEMS-A
ConnectorX001-TransmissionSpeedSensor31
ConnectorX002-TurbineSpeedSensor32 .................................
ConnectorX003-EngineSpeedSensor33
ConnectorX004-TransmissionINPUT/OUTPUT34 ..........................
ConnectorX007-TransmissionController35
ConnectorX008-TransmissionController36
ConnectorX010-RightConsoleHarness(RC)toMainHarness(MH)37
ConnectorX011-CheckTransmissionIndicator39
ConnectorX012-RangeInhibitIndicator40 .................................
10
BOOK2-87693297 ElectricalPowerSystem-30(Continued) CONTENTS SectionDescription Page Relay 20 Removal20 ............................................................. TestProcedure20 Switches 20 ................................................................ ButtonSwitch20 RockerSwitch21 ........................................................ MomentaryRockerSwitch21 Multi-FunctionHandle(MFH)Switches21 ................................... Diodes 22 TestProcedure22 Electro-hydraulicSolenoidValveCoils23 ElectricalSystemComponentsChart24 DistributionSystems,ElectricalPowerSystem29 Introduction 29 Connectors 29 .............................................................. HarnessSplices29 Fuses,Relays,andSwitches29 ............................................... SwitchandRelayContacts29 Grounds 29 ................................................................. PowerSources29 WireHarnessIdentification29 ................................................. WireColorCodes30 WiringHarness-ComponentDiagram31 .......................................
DISTRIBUTIONSYSTEMS-A
BOOK2-87693297
ElectricalPowerSystem-30(Continued)
CONTENTS
SectionDescription Page
ConnectorX013-Speedometer41
ConnectorX014-DiagnosticsConnector42 .................................
ConnectorX015-PistonPumpManifold(PPM)43
ConnectorX016-PistonPumpManifold(PPM)44 ............................
ConnectorX017-PistonPumpManifold(PPM)45
ConnectorX018-RightSideSensor46 .....................................
ConnectorX019-BaleLoaderDownSensor47
ConnectorX020-1stTableUpLimitSensor48 ..............................
ConnectorX021-GearPumpManifold(GPM)49
ConnectorX022-FuelSolenoid50
ConnectorX023-2ndTable50° Sensor51
ConnectorX024-2ndTableUpSensor52
ConnectorX025-2ndTableDownSensor53
ConnectorX026-LeftPush-OffFeetHomeSensor54
ConnectorX027-ElectronicController55 ...................................
ConnectorX028-ElectronicController56
ConnectorX029-ElectronicController57 ...................................
ConnectorX030-GateSwitch58
ConnectorX033-ACBlowerResistor59 ....................................
ConnectorX034-ACBlowerMotor59
ConnectorX038-FanReverseSolenoid(ifequipped)60 ......................
ConnectorX039-FuelLevelIndicator61
ConnectorX040-ParkBrakeIndicator62 ...................................
ConnectorX041-AlternatorIndicator63
ConnectorX042-OilPressureIndicator64 ..................................
ConnectorX043-ThrottlePositionSensor65
ConnectorX045-StartSolenoidMotor65 ...................................
ConnectorX048-IgnitionSwitch66
ConnectorX050-OperatorPanel67
ConnectorX054-CabInteriorLight68
ConnectorX055-CabInteriorLight69
ConnectorX062-EngineTemperatureIndicator70 ...........................
11
DISTRIBUTIONSYSTEMS-A
BOOK2-87693297
ElectricalPowerSystem-30(Continued)
CONTENTS
SectionDescription Page
ConnectorX066-RHShifter71
ConnectorX067-FuelSender72 ..........................................
ConnectorX068-FuelGauge73
ConnectorX069-OilPressureGauge74 ....................................
ConnectorX069-OilPressureSensor75
ConnectorX070-AlternatorBiasResistor76 ................................
ConnectorX071-Alternator76
ConnectorX075-TurnSignal-High/LowBeamSwitch77 .....................
ConnectorX078-AxleRangeSwitch78
ConnectorX080-Tachometer79
ConnectorX082-Voltmeter80
ConnectorX083-LoadRackDownSensor81
ConnectorX089-ACHighPressureSwitch82
ConnectorX090-ACCompressorClutch83
ConnectorX092-CellPhoneJack84 .......................................
ConnectorX093-CommunicationRadioJack84
ConnectorX094-HVACModeSelectSwitch85 ..............................
ConnectorX095-FanSpeedSwitch86
ConnectorX104-HeaterMotor(ifequipped)86 ..............................
ConnectorX105-ACBlowerMotor87
ConnectorX106-ThermostatSwitch87 .....................................
ConnectorX107-ACLowPressureSwitch88
ConnectorX110-WindshieldWiperSwitch(ifequipped)88 ....................
ConnectorX111-WindshieldWiperMotor(ifequipped)89
ConnectorX113-BrakeLightSwitch89 .....................................
ConnectorX114-BrakeFlowSwitch90
ConnectorX115-BrakeBoostMotor90 .....................................
ConnectorX116-FlasherModule91
ConnectorX117-HazardLightsSwitch92
ConnectorX118-Road/FieldLightSwitch93
ConnectorX119-ConsoleOverheadLight94
ConnectorX120-RightFrontWorkLight95 .................................
12
DISTRIBUTIONSYSTEMS-A
BOOK2-87693297
ElectricalPowerSystem-30(Continued)
CONTENTS
SectionDescription Page
ConnectorX121-LeftFrontWorkLight96
ConnectorX122-LeftRearWorkLight97 ...................................
ConnectorX123-SideWorkLight98
ConnectorX124-RearWorkLight99 .......................................
ConnectorX125-LeftBrakeLight100
ConnectorX126-RightBrakeLight101 .....................................
ConnectorX127-LeftHeadlamp102
ConnectorX128-RightHeadlamp103 ......................................
ConnectorX131-Water/CoolantLevelSwitch104
ConnectorX133-EngineCoolantTemperatureGauge105
ConnectorX134-WaterTemperatureSensor106
ConnectorX136-AxleRangeMotor107
ConnectorX137-RightRearWorkLight(ifequipped)108
ConnectorX144-LeftSideHazardLight109
ConnectorX145-RightSideHazardLight110 ...............................
ConnectorX146-FrontLeftHazardLight111
ConnectorX147-FrontRightHazardLight112 ..............................
ConnectorX148-RearLeftHazardLight113
ConnectorX149-RearRightHazardLight114 ...............................
ConnectorX150-RearLeftTurnLight115
ConnectorX151-RearRightTurnLight116 .................................
ConnectorX152-MainHarnesstoRearLoadRackHarness117
ConnectorX153-CabDashHarnesstoRightConsoleHarness118 ............
ConnectorX154-TieSpikeSensor(BW28)119
ConnectorX154-TieSpikeSensor(BW38)120 ..............................
ConnectorX155-1stTableLeftTripSensor121
ConnectorX157-MultifunctionHandle(MFH)122 ............................
ConnectorX159-IndicatorPanel,LHTurn123
ConnectorX160-IndicatorPanel,HazardLights124
ConnectorX161-IndicatorPanel,HighBeam125
ConnectorX162-IndicatorPanel,RightTurn126
ConnectorX171-AirSeatAssembly127 ....................................
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DISTRIBUTIONSYSTEMS-A
BOOK2-87693297
ElectricalPowerSystem-30(Continued)
CONTENTS
SectionDescription Page
ConnectorX171-Radio(ifequipped)128
ConnectorX171-Radio(ifequipped)129 ...................................
ConnectorX173-RightSpeaker130
ConnectorX173-RightPush-offFeetHomeSensor131 ......................
ConnectorX174-LeftSpeaker132
ConnectorX174-FrontCANTerminationResistor133 ........................
ConnectorX202-FanGearPumpOilSolenoid134
ConnectorX207-FuelGauge135 ..........................................
ConnectorX209-FuelGauge136
ConnectorX210-FuelGauge137
ConnectorX211-Voltmeter138
ConnectorX212-Voltmeter139
ConnectorX214-WaterTemperatureGauge140
ConnectorX215-WaterTemperatureGauge141
ConnectorX216-WaterTemperatureGauge142 .............................
ConnectorX217-EngineOilPressureGauge143
ConnectorX218-EngineOilPressureGauge144 ............................
ConnectorX219-EngineOilPressureGauge145
ConnectorX220-TurnSignal/High-LowBeamSwitch146 .....................
ConnectorX221-RightConsoletoOverheadInstruments147
ConnectorX222-RightConsoletoOverheadInstruments148 .................
ConnectorX224-DiodeModule149
ConnectorX226-MainHarnesstoTransmissionHarness150 .................
ConnectorX232-Alternator(Bosch)151
ConnectorX233-Alternator(Bosch)151 ....................................
ConnectorX234-NeutralStart/BackupSwitch152
ConnectorX236-ACHighPressureSwitch153 ..............................
ConnectorX237-FuelSender154
ConnectorX238-JunctionBlock155
ConnectorX239-JunctionBlock156
ConnectorX240-JunctionBlock157
ConnectorX241-JunctionBlock158 .......................................
14
SectionDescription
DISTRIBUTIONSYSTEMS-A
15
BOOK2-87693297
CONTENTS
ElectricalPowerSystem-30(Continued)
Page
Battery 160
BatterySizeandRating160 HowaBatteryWorks160
Troubleshooting160 DeterminingtheCauseofBatteryFailure161
BatteryApplicationandInstallation161 BatteryServiceHistory161
VisualInspection161
BatteryCase162
NegativePlates163
ìKeyOffîCurrentDrain165 VoltageDropTest166
ChargingtheBattery167
ConnectorX242-JunctionBlock159
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BatteryAgeandDateCoding162 OverchargingandUndercharging162
Electrolyte162 IntercellConnectionsandTerminalPosts162 PositivePlates162 .......................................................
Sulfation163 ............................................................ TroubleshootingSummary163 TestingtheBattery-General164 .................................................. BatteryStateofCharge-OpenCircuitVoltage164 BatteryCapacityTest(LoadTest)-HighRateDischarge165 ...................
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DeterminingBatteryChargeProcedure167 ..................................... SlowChargeProcedure:forBatteriesWithChargesBelow11.0V167 SelectingBatteryChargingMethod168 ............................................ SlowChargeProcedure169
StandardChargeProcedure:PreferredMethodforBatteries170 WithVoltageOf11-12.5V170 ................................................ FastChargeProcedure:AlternativeMethodforBatteries WithVoltagesof11-12.5V170 ............................................... BatteryChargingPrecautions171
SectionDescription
DISTRIBUTIONSYSTEMS-A
AlternatorConnections(Bosch)174
AlternatorConnections(ISKRA)174
BoschTechnicalData174
BoschTorqueSpecifications174
ISKRATechnicalData175
ISKRATorqueSpecifications175 ........................................... FieldExcitationResistor(R-06)175
AlternatorandVoltageRegulatorPrecautions175 ............................
TestProcedure1:ContinuityTestforOpenCircuits179
TestProcedure2:ContinuityTestforShorttoGround180
TestProcedure3:ResistanceTestforElectricalComponents181 ..................
TestProcedure4:VoltageMeasurement182
16
BOOK2-87693297
CONTENTS
ElectricalPowerSystem-30(Continued)
Page BatterySpecifications171 ChargingSystem172 ............................................................ Introduction172 ChargingSystemExcitationCircuit173 ......................................... Alternator 173 Maintenance173 ......................................................... BeltTension173 AlternatorDriveBelt173
Removal173
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Alternator 176 ............................................................... Removal176 Installation177 ........................................................... Testing 178
AlternatorRemovalandInstallation176
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Troubleshooting183 ............................................................. BatteryisOvercharged183 BatteryisUndercharged183 NoOutputCheck184 RatedOutputCheck185 ElectricalSchematics186 ........................................................
17 DISTRIBUTIONSYSTEMS--A BOOK3-87693298 LightingSystem--40 CONTENTS SectionDescription Page GeneralInformation4 LampReplacementChart4 .................................................... WiringDiagrams5 WireHarnessesandConnectors6 ................................................. OIWireHarness6 RCWireHarness8 ........................................................... LightIndicatorTower10 MH/WireHarness(Rear)13 ................................................... Roadvs.WorkLights16 Operation 16 Headlights 16 Operation 16 Removal 17 Adjustment 18 WorkLights 18 ................................................................. Operation 18 FrontWorkLightsRemoval19 ................................................ SideWorkLightsRemoval20 RearWorkLightsRemoval20 ................................................. Replacement21 Adjustment 22 .............................................................. Hazard/WarningLights22 Operation 22 ................................................................ RearHazard/WarningLightsRemoval23 CabHazard/WarningLightsRemoval24 ........................................ CabTurnSignal\FlasherBulbReplacement25 TurnSignalLights26 ............................................................ Operation 26 Removal 26 FlasherModule 27 Operation 27
DISTRIBUTIONSYSTEMS--A
Path1(LoaderWorkLightE-21)38 .........................................
Path2(TopLHWorkLightE-19)39
Path2(TopRHWorkLightE-18)39
Path3(LHSecondTableWorkLightE-20)39
Path3(RHSecondTableWorkLightE-08)IfEquipped39
Path3(RHConsoleLightE-17)40
Path4(RearWorkLightE-22)40
18
BOOK3-87693298 LightingSystem--40(Continued) CONTENTS SectionDescription Page BrakeLights 27 Operation 27 ................................................................ Removal 28 BrakeLightSwitchAdjustment28 .............................................. DomeLight 28 Operation 28 ................................................................ Removal 29 ConsoleLight 30 ................................................................ Operation 30 Removal 31 IndicatorLightPanel31 Operation 31 Removal 32 LightingSystemSwitchReplacement33 Road\workLightSwitch(S-25)33 .............................................. HazardLightSwitch(S-24)33 TurnSignal/Hi-LoBeamSwitch(S-14)34 ....................................... BrakeLightSwitch(S-22)34 CircuitDescriptions35 ........................................................... Headlights(Low-beam)35 Path1(ToMarkerLightFuseF-25)35 ...................................... Path2(ToHighBeamRelayK-06)36 Headlights(High-beam)36 .................................................... WorkLights 38
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DISTRIBUTIONSYSTEMS--A
SectionDescription
FlasherModule(A-02)Left-GroupedCircuits41 .................................
LHFrontHazardLight(E-34)41
LHSideHazardLight(E-32)41 ............................................
LHRearHazardLight(E-36)41
FlasherModule(A-02)Right-GroupedCircuits41
19
BOOK3-87693298
LightingSystem--40(Continued) CONTENTS
Page HazardLights40
BrakeLights 43 InteriorLights43 RHConsoleLight(E-17)43 ............................................... DomeLight(E-41)44 IndicatorLights44 ........................................................... LightIndicatorDisplay(E-40)44 Troubleshooting 55 ..............................................................
................................ RHFrontHazardLight(E-35)41 RHSideHazardLight(E-33)42 ............................................ RHRearHazardLight(E-37)42 TurnSignalLights42 Left-groupedCircuits42 Right-groupedCircuits43
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