New holland t8030 tractor service repair manual

SERVICE MANUAL
T8010 [Z8Rx06001 - ]
T8020 [Z8Rx06001 - ]
T8030 [Z8Rx06001 - ]
T8040 [Z8Rx06001 - ]
T8050 [Z8Rx06001 - ]
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Contents
INTRODUCTION
DISTRIBUTION SYSTEMS.............................................................A
PRIMARY HYDRAULIC POWER SYSTEM............................................... A.10.A
PRIMARY HYDRAULIC POWER SYSTEM Electro-hydraulic remote valve.............. A.10.C
PNEUMATIC SYSTEM .................................................................... A.20.A
ELECTRICAL POWER SYSTEM ......................................................... A.30.A
LIGHTING SYSTEM....................................................................... A.40.A
ELECTRONIC SYSTEM .................................................................. A.50.A
FAULT CODES ............................................................................ A.50.A
POWER PRODUCTION .................................................................B
ENGINE ................................................................................... B.10.A
FUEL AND INJECTION SYSTEM......................................................... B.20.A
ENGINE COOLANT SYSTEM ............................................................ B.50.A
LUBRICATION SYSTEM .................................................................. B.60.A
STARTING SYSTEM ...................................................................... B.80.A
POWER TRAIN.............................................................................C
TRANSMISSION Powershift .............................................................. C.20.E
REAR PTO Hydraulic..................................................................... C.40.C
BAR AXLE................................................................................. C.60.A
TRAVELLING................................................................................D
FRONT AXLE ............................................................................. D.10.A
2WD-4WD SYSTEM Hydraulic........................................................... D.14.C
STEERING Hydraulic..................................................................... D.20.C
SERVICE BRAKE Hydraulic.............................................................. D.30.C
PARKING BRAKE Hydraulic ............................................................. D.32.C
BRAKE CONNECTION Hydraulic ........................................................ D.34.C
BRAKE CONNECTION Pneumatic........................................................ D.34.E
SUSPENSION Hydraulic ................................................................. D.40.C
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WHEELS AND TRACKS Wheels......................................................... D.50.C
BODY AND STRUCTURE ..............................................................E
SHIELD.................................................................................... E.20.A
USER CONTROLS AND SEAT ........................................................... E.32.A
USER CONTROLS AND SEAT Operator seat ............................................ E.32.C
USER PLATFORM ........................................................................ E.34.A
ENVIRONMENT CONTROL Heating, ventilation and air-conditioning.................... E.40.D
SAFETY SECURITY ACCESSORIES Safety ............................................. E.50.B
WORKING ARM............................................................................H
HITCH Rear hitch......................................................................... H.10.C
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INTRODUCTION
WARNING
Hydraulic fluid escaping under pressure can have enough force to penetrate the skin. Hydraulic fluid may
also infect a minor cut or opening in the skin. If injured by escaping fluid, see a doctor at once. Serious
infection or reaction can result if medical treatment is not given immediately. Make sure all connections are
tight and that hoses and lines are in good condition before applying pressure to the system. Relieve all
pressure before disconnecting the lines or performing other work on the hydraulic system. To find a leak
under pressure use a small piece of cardboard or wood. Never use hands. Failure to comply could result in
death or serious injury.
M252A
WARNING
When removing hardened pins such as a pivot pin, or a hardened shaft, use a soft head (brass or bronze)
hammer or use a driver made from brass or bronze and a steel head hammer.
M497
WARNING
When using a hammer to remove and install pivot pins or separate parts using compressed air or using a
grinder, wear eye protection that completely encloses the eyes (approved goggles or other approved eye
protectors).
M498
WARNING
Use suitable floor (service) jacks or chain hoist to raise wheels or tracks off the floor. Always block machine
in placed with suitable safety stands.
M499
WARNING
When servicing or repairing the machine. Keep the shop floor and operators compartment and steps free of
oil, water, grease, tools, etc. Use an oil absorbing material and or shop cloths as required. Use safe practices
at all times.
M500
WARNING
Batteries contain acid and explosive gas. Explosions can result from sparks, flames or wrong cable con-
nections. To connect the jumper cables correctly to the battery of this machine see the Operators Manual.
Failure to follow these instructions can cause serious injury or death.
M504
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4

DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Hydraulic pump - Dynamic description
T8010, T8020, T8030, T8040, T8050
The tractor uses three hydraulic pumps which are driven through a drive housing on the right side of the range trans-
mission. The pump drive housing gears are driven by the PTO drive line and all the pumps turn at approximately 1.33
times engine speed. A PFC (pressure and flow compensating) piston pump is attached to the front of the pump drive
housing, while the tandem gear pumps are attached to the rear of the pump drive housing.
The front section of the tandem gear pump supplies the regulated pressure circuit: brake valve, transmission control
valves, PTO and differential lock valve, auxiliary and hitch valve pilot circuits. The rear section supplies charge flow to
the PFC pump(s). The PFC pump supplies flow to the priority valve, which directs flow to the steering system, remote
valves and the three point hitch.
All hydraulic lines are equipped with O-ring face seals to ensure reliable, vibration-resistant connections.
Charge/lubrication pump
The charge/lubrication pump is the rear section of the dual gear pump and it is used to supply the main PFC pump
with a charged inlet condition to prevent cavitation. The pump also supplies lubrication and cooling requirements for
the transmission.
The pump draws oil from the transmission housing through a 100 mesh suction screen. The pump flow is directed
across the main filter assembly to provide clean charge and lubrication oil.
The pump flow rate at rated speed 2667 RPM( 2000 RPM engine speed) is 177.0 l/min (47.0 US gpm).
Regulated circuit pump
The regulated circuit pump is the front section of the tandem gear pump. The pump draws oil from the system reservoir
through a 100 mesh suction screen. The pump flow passes through the regulated circuit filter housing and into the
priority regulator valve. The priority regulator valve maintains the regulated pressure circuit at 22.4 - 24.5 bar (325
- 355 psi). The regulated pump flow supplies the PTO/differential lock valve, transmission control valves and brake
valve. The remote and hitch valves are also supplied with regulated pressure.
Once these circuits are satisfied, the excess regulated pump flow is directed through the oil coolers and joins up with
the charge pump flow at the downstream side of the main filter head.
The pump flow rate at rated speed of 2667 RPM ( 2000 RPM engine speed) is 102.0 l/min (27.0 US gpm).
PFC piston pump
The axial piston pump has a variable flow output and can operate at variable pressures. The pump matches the
hydraulic power output to the actual load requirements to ensure maximum efficiency and the minimum use of fuel.
The pump inlet is charged to prevent cavitation. The pump output flow is supplied to the priority regulator valve. The
priority regulator valve gives top priority to the steering system and trailer brake circuit. Once the steering system and
trailer brake circuits are satisfied the priority regulator valve supplies pump flow to the remote auxiliary valves and
three point hitch valve.
The maximum pump flow rate for the standard pump at rated speed of 2667 RPM ( 2000 RPM engine speed) is 146.0
l/min (38.6 US gpm).
NOTE: The standard pump system delivers approximately 113.6 l/min (30.0 US gpm) through a single remote sec-
tion. This is due to resistance created by oil flowing through restrictive passage ways and long lengths of tubing or
hose.
Optional high flow PFC piston pump
An optional high flow PFC piston pump is available. The high flow rate maximum pump flow rate at rated speed of
2667 RPM ( 2000 RPM engine speed) is 220 l/min (58 US gpm).
NOTE: The high flow pump system delivers approximately 113.6 l/min (30.0 US gpm) through a single remote sec-
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hose. However, when operating two or more remote sections the high flow pump has approximately 75.7 l/min (20.0
US gpm) more flow than a standard pump system to supply the additional remote circuits.
RCPH07CCH026FAE 1
1. Charge/lubrication pump outlet (rear section) 3. High flow PFC piston pump
2. Regulated circuit pump outlet (front section) 4. Dual gear pump/regulated system filter housing
Optional Megaflow PFC piston pump
The axial piston pump has a variable flow output and can operate at variable pressures. The pump matches the
hydraulic power output to the actual load requirements to ensure maximum efficiency and the minimum use of fuel.
The maximum pump flow rate at rated speed 2667 RPM( 2000 RPM engine speed) is 117.0 l/min (31.0 US gpm).
The pump inlet is charged to prevent cavitation. The pump output flow is supplied directly to the remote auxiliary
manifold. The manifold is equipped with internal plugs to separate the dual flow supply flow, signal line pressure and
signal line pilot relief from the standard PFC piston pump circuit. The Megaflow pump supplies only the third, fourth
or fifth remote sections. The two PFC pump hydraulic circuits operate independently.
NOTE: The Megaflow pump system delivers approximately 113.6 l/min (30.0 US gpm) through a single remote sec-
hose.
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RCPH07CCH027FAE 2
1. Megaflow signal line 4. Standard PFC pump
2. Megaflow outlet 5. Megaflow inlet
3. Megaflow PFC pump 6. Main filter assembly
Lubrication circuit
The lubrication flow is a combination of both dual gear pumps’ outputs – filtered charge pump flow and filtered/cooled
excess regulated circuit flow. Inlet charge pressure and lubrication are limited to 5.0 bar (75 psi) by a lube relief valve.
The lubrication circuit provides a low pressure flow of oil to lubricate and cool the following transmission components:
master clutch, bevel pinion gears, brakes, drop box, odd/even clutches, MFD/range, creep drive and PTO/differential
lock lube.
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RCPH07CCH029FAE 3
1. Left brake lube 6. Drop box lube
2. PTO lube supply 7. Right brake lube
3. Range lube 8. Charge pump to filter inlet
4. Master clutch lube
5. Odd/even lube
9. Oil cooler return to filter
RCPH07CCH021AAE 4
10. Lube relief hose
11. Drop box output lube (without creeper)
12. Drop box rear bearing lube
Regulated pressure circuits
The regulated circuit is supplied by the front dual gear pump. The pump flow passes through the regulated circuit
filter housing and onto the priority regulator valve. The pressure regulator portion of the valve maintains the regulated
pressure at 22.4 - 24.5 bar (325 - 355 psi).
The following components are supplied by the regulated circuit:
• speed transmission powershift valve,
• odd/even transmission powershift valve (includes creep and park brake),
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• range transmission powershift valve (includes MFD),
• PTO/differential lock valve,
• master clutch inching valve,
• brake valve,
• hitch valve pilot pressure,
• remote valve pilot pressure
• and MFD clutch supply.
RCPH07CCH023FAE 5
1. Range regulated supply tube 5. Master clutch diagnostic tube (See next view.)
2. Speed transmission control valve regulated supply,
upper tube
6. Transmission control valve regulated supply
3. Priority regulator valve to PTO valve
4. Priority regulator valve
7. Priority regulator valve excess to oil coolers
NOTE: Brake, hitch and remote valves regulated supply tubes not shown.
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RCPH07CCH022FAE 6
1. Master clutch diagnostic coupler
RCPH07CCH028BAE 7
2. Regulated circuit accumulator 3. Speed transmission control valve regulated supply,
lower tube
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Tandem gear pump Charge and lubrication - Component
identification
T8010, T8020, T8030, T8040, T8050
RCPH07CCH020BAE 1
RCPH07CCH021BAE 2
1. Pump assembly 5. Lube relief valve assembly
2. Priority regulator valve 6. Pump inlet section
3. Regulator section inlet
4. Regulated circuit filter
7. Suction screen shroud
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Motor return - Component identification
T8010, T8020, T8030, T8040, T8050
1. Case drain coupler
2. Motor return coupler
3. Motor return tube
RCPH07CCH034BAE 1
RCPH07CCH020AAE 2
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Pump drive - Exploded view
T8010, T8020, T8030, T8040, T8050
RCPH07CCH653FBC 1
1. Pump drive housing 7. Bearing cup
2. Idler shaft 8. Bearing cone
3. Bearing 9. Driven gear
4. Spacer 10 Shim
5. Retaining ring 11. O-ring
6. Idler gear 12. Bearing cone
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Control valve Priority/Regulator valve - Dynamic description
T8010, T8020, T8030, T8040, T8050
The priority/regulator valve assembly is located on the top right side of the range transmission. The assembly
contains:
• the priority spool,
• the regulator spool,
• and steering relief valve.
The front section of the dual gear pump and the pressure and flow compensating (PFC) piston pump supply oil to the
priority/regulator valve.
Priority spool ( supplied by the PFC piston pump)
Oil flows into the priority/regulator valve from the left side port (2). Steering has first priority: oil flows across the
priority spool (11) and out the steering supply port (3). There is a cross-drilled passage near the top of the priority
spool. Oil enters this orifice and starts to build pressure against the spring. As steering demand is satisfied, pressure
builds on the top of the priority spool and the spool moves down against its spring, opening a passage to the remote
and hitch circuits (13).
When the steering circuit is placed on demand, a pressure drop is created on the top end of the priority spool. Signal
and spring pressure work against pump outlet pressure, and the priority spool moves up to accommodate steering
demand.
Once steering demand is satisfied, pressure builds on the top of the priority spool and the spool shifts down to increase
flow to the remote and hitch circuits. When equipped with trailer brakes, oil is also supplied from the priority valve to
the trailer brakes.
RCPH07CCH004FAE 1
1. Priority regulator valve 7. Regulated supply
2. Supply from PFC pump 8. Regulated pressure adjustment
3. Supply to steering 9. Steering relief adjustment
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4. Regulated supply to system 10. Steering signal to hand pump
5. Excess flow to coolers 11. Priority spool
6. Regulated supply to brakes 13. Supply to remote valves
RCPH07CCH016GAE 2
1. Priority regulator valve 8. Regulated pressure adjustment
2. Supply from PFC piston pump 9. Steering relief adjustment
3. Supply to steering 10. Steering signal to hand pump
4. Regulated supply to system 11. Priority spool
5. Excess flow to coolers 12. Regulator spool
7. Regulated supply 14. Internal plug
Regulator spool (supplied by regulated pump section)
Regulated pump flow enters the priority/regulator valve at the right side port (7). Oil flows across the regulator spool
(12) and supplies all the regulated circuits through the side port (6) and top port (4). The oil also flows through the
orifice near the top of the regulator spool. This oil builds pressure and moves the regulator spool against the spring.
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This regulates pressure and maintains the 22.4 - 24.5 bar (325 - 355 psi) in the regulated circuits. These include the
transmission control valves, PTO/differential lock valve, brake valve and regulated pressure for remote valve and the
hitch valve pilot pressure.
When all regulated circuit demands are met, the regulator spool continues to maintain the 22.4 - 24.5 bar (325 - 355
psi) pressure and allows excess pump flow out the cooler supply port (5).
When a regulated circuit is activated, the regulator spool senses a momentary drop in pressure. The spring will
overcome the spool and move it up to increase flow of oil to meet the demand. As the demand is met, pressure again
builds on the top side of the spool through the orifice and moves the spool down to maintain regulated pressure.
RCPH07CCH004FAE 3
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RCPH07CCH016GAE 4
Priority regulator valve with pressure solenoid
NOTE: T8050 only.
The priority/regulator valve equipped with a pressure solenoid valve (1) which is not adjustable. The pressure solenoid
uses feedback from the pressure transducer, through the transmission controller, to maintain a tighter tolerance on
regulated system pressure. The solenoid maintains full regulated pressure to the transmission clutches regardless of
temperature or other demands on the regulated pressure circuit.
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RCPH07CCH020GAE 5
1. Pressure solenoid valve
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Control valve Priority/Regulator valve - Exploded view
T8010, T8020, T8030, T8040
RCPH07CCH028GAE 1
1. Priority/regulator valve body 5. Pilot relief assembly
2. Priority valve spool 6. Orifice fitting
3. Regulator spool 7. Regulated pressure adjustment assembly
4. Logic check valve assembly 8. Internal plug
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Control valve Priority/Regulator valve - Sectional view
T8010, T8020, T8030, T8040
RCPH07CCH016GAE 1
1. Priority and regulator valve 7. Regulator spool
2. Logic check valve assembly 8. Regulator spring
3. Internal plug 9. Lock nut
4. Priority spring 10. Adjusting plug
5. Priority valve spool 11. Pilot relief valve assembly
6. Plug 12. Orifice fitting body assembly
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Control valve Priority/Regulator valve - Exploded view
T8050
RCPH07CCH027GAE 1
1. Priority/regulator valve body 7. Outer spring
2. Priority valve spool 8. Piston
3. Regulator spool 9. Inner spring
4. Logic check valve assembly 10. System pressure valve block
5. Pilot relief assembly
6. Orifice fitting
11. System pressure solenoid valve
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Control valve Priority/Regulator valve - Sectional view
T8050
RCPH07CCH020GAE 1
1. Priority and regulator valve 7. Regulator spool
2. Logic check valve assembly 8. Inner spring
3. Internal plug 9. Outer spring
4. Priority spring 10. Piston
5. Priority valve spool 11. System pressure solenoid assembly
6. Plug 12. Orifice fitting body assembly
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Pressure/flow compensating (PFC) pump - Dynamic description
T8010, T8020, T8030, T8040, T8050
NOTE: The principles of operation for the standard flow pump apply to both the optional high flow pump and Megaflow
pump systems. The illustrations below depict the standard flow pump.
Principle of Control
All remote valves, the hitch control valve, the optional trailer brake and optional power beyond circuit contain a signal
port. Each signal port directs a signal pressure, equal to the working pressure of that circuit, through signal lines
and check valves to the pump compensator spool. The compensator angles the pump swash plate to meet system
demands.
A check valve is located in each signal line between the control valves and the compensator spool. If several control
valves are operated at the same time, the signal line at the highest pressure causes the other check valve(s) at the
lower pressures to seat themselves. This prevents signal bleed off through other control valves and ensures that the
highest signal pressure acts on the compensator spool.
The pump is designed to operate in two different modes according to the demand for flow and pressure. The
modes ares:
• Low pressure standby: When there is no demand for flow or pressure, the pump provides just enough flow to
make up for internal leakage in the hydraulic system at low pressure. In this mode the pump requires very little
power to drive it.
• Pressure/flow delivery and compensation: When there is a demand for flow and pressure from the hydraulic sys-
tem, the pump responds to provide only the flow required. This limits the power consumption of the system.
RCPH07CCH003GAE 1
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1. Control piston 7. Piston block loading spring
2. Control spring 8. Piston block
3. Drive set 9. Back plate
4. Pump housing 10. Compensator assembly
5. Swash plate 11. Control piston rod
6. Piston
RCPH07CCH037FAE 2
Pressure compensator
1. Signal line pressure 6. High pressure compensator spool
2. Pump case drain 7. High pressure spring
3. Control piston pressure 8. Compensator assembly
4. Piston pump outlet pressure 9. Flow compensator springs
5. Flow compensator spool 10. Orifice plug
Low pressure stand by
When there is no demand for flow, there is no pressure signal feedback to the pump, and the pump enters low pressure
standby mode. Since there is no place for pump oil to flow, pressure builds at the pump outlet passage. This pressure
is directed, through internal passages in the pump back plate, to the end of the compensator spool opposite the spring.
The spring acting on the flow compensator spool allows the spool to move at a 23.5 - 27.0 bar (340 - 390 psi) differ-
ential pressure. At this pressure, the flow compensator spool moves down and allows oil to flow into the passage to
the pump control piston.
Pressure on this control piston tilts the pump swash plate against the swash plate control spring to a near neutral
position. In this condition, the pump provides just enough flow to make up for internal leakage, thus maintaining a
minimum system pressure of 23.5 - 27.0 bar (340 - 390 psi).
The pump remains in the low pressure standby position as long as there is no pressure or flow demand from the
hydraulic system. In this mode, the pump produces very little heat and absorbs very little horsepower from the engine.
Engine Start Up
Before the engine is started, the pump swash plate angle is at its maximum angle. As soon as the engine is cranked
by the starter motor, the pressure and flow compensating (PFC) pump produces flow and pressure builds in the pump
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delivery passage. When this pressure reaches 23.5 - 27.0 bar (340 - 390 psi) the pump enters its low pressure
standby mode. This occurs almost instantly and makes engine starting easier.
Pressure/flow delivery and compensation
When oil is required in the system, flow is controlled by the difference in pressure at opposite ends of the compensator
spool.
When a control valve is operated, pressure at the outlet of the piston pump drops slightly. Spring and signal line
pressure shift the flow compensator spool away from the spring end, allowing oil from the control piston to drain past
the spool and to tank.
As the oil drains out of the control piston, the swash plate angle increases and pump flow rises until the flow demand
has been met. The flow from the pump is determined by the size of the orifice in the control valve which is being
operated. This orifice is created by limiting the main valve spool travel within the control valve.
When a control valve is operated, oil pressure in the circuit being supplied increases to its operating pressure. This
pressure is transmitted through the sensing line to the spring end of the compensator spool.
Increased flow demand
When an additional control valve is operated, pressure drops slightly at the pump pressure passage. The compen-
sator spool moved up and allows the oil behind the control piston to drain to tank. The swash plate moves and pump
flow increases until the extra demand for flow has been met.
Pressure at the pump outlet increases until it is 23.5 - 27.0 bar (340 - 390 psi) above the signal line pressure. This
pressure increase moves the pump compensator spool against the spring, allowing sufficient flow past the spool to
the control piston. This action on the piston moves the swash plate to a position where increased flow is maintained
and the pressure stabilized.
Decreased flow demand
When flow demand is reduced, pump pressure increases until the pump outlet pressure exceeds the signal line pres-
sure by more than 23.5 - 27.0 bar (340 - 390 psi). The flow compensator spool moves down to allow some oil to flow
into the pump control piston. This action on the piston destrokes the pump against the spring and reduces pump flow.
When pump flow falls to match the reduced demand, the difference in pressure sensed on the opposite sides of the
compensator spool returns to 23.5 - 27.0 bar (340 - 390 psi). The compensator spool moves and blocks off the
passage to the control piston, which locks the swash plate at that pumping angle.
High pressure standby
The hydraulic system is protected by limiting its maximum pressure to 202 - 203 bar (2930 - 2950 psi) through a
signal relief valve. This protection is required, for example, when a hydraulic cylinder reaches the end if its stroke or
when an unconnected remote valve is operated.
NOTE: Hitch system pressure is not limited by a signal relief valve. Hitch system maximum pressure limit is 224 bar
(3250 psi).
When system pressure reaches the setting of the high pressure compensator spool, the pump high pressure com-
pensator spool shifts against its spring, allowing the full pump pressure to be applied to the pump control piston. This
destrokes the pump very rapidly from full stroke to almost zero (within 8 to 10 milliseconds). The swash plate stabi-
lizes to provide just sufficient flow to make up for internal leakage.
The pump remains in the high pressure standby mode until the valve in operation returns to neutral. When this occurs,
signal line feed from the valve is cut off. Signal pressure drops because the drain orifice plug passage is open to the
pump case drain. When there is no signal line pressure, the pump immediately returns to a low pressure standby
condition.
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Pressure/flow compensating (PFC) pump Standard - Component
identification
T8010, T8020, T8030, T8040, T8050
RCPH07CCH025FAE 1
RCPH07CCH017FAE 2
1. Remote manifold load sense tube 6. PFC piston pump
2. PFC pump to priority regulator valve 7. Remote manifold return (tube)
3. Remote manifold return (hose) 8. Remote manifold supply
4. Main filter assembly
5. Pump load sense
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Pressure/flow compensating (PFC) pump High flow - Component
identification
T8010, T8020, T8030, T8040, T8050
RCPH07CCH018FAE 1
RCPH07CCH017FAE 2
1. Remote manifold load sense tube 6. High flow PFC piston pump
2. PFC pump to priority regulator valve 7. Remote manifold return (tube)
3. Remote manifold return (hose) 8. Remote manifold supply
4. Main filter assembly
5. Pump load sense
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Pressure/flow compensating (PFC) pump Dual flow - Component
identification
T8010, T8020, T8030, T8040, T8050
RCPH07CCH027FAE 1
RCPH07CCH030FAE 2
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New holland t8030 tractor service repair manual

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