Part of the New Holland Repair Manuals.
This BW28 and BW38 bale wagon repair manual gives the Stack Command electronics a full chapter. It covers ECU connections, stack patterns, machine interlocks, input and output tests and proximity sensor checks.
From there it widens out across seven books, part number 87693295, first printed in 2007. It covers the engine, fuel, cooling, the Allison automatic transmission, axles, TRW steering gear, Hydro-max brakes and cab A/C. The crop end gets the same depth: bale loader, cross-conveyor, both tables, tie spikes, load rack, rolling rack and push-off.
What's Inside This New Holland BW28, BW38 Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Complete Contents | 1-60 | Section Index, Book Numbers, Chapter Contents, Manual Organization |
| Primary Hydraulic Power System | 61-248 | Piston Pump, Double Gear Pump, Valve Manifolds, Load Sensing, Filtration, Hydraulic Circuits, Pressure Testing, Troubleshooting |
| Electrical Power System | 249-474 | Ground Points, Fuses, Relays, Wire Harnesses, Connectors, Battery, Alternator, Starter Circuits |
| Lighting System | 475-534 | Headlights, Work Lights, Hazard Lights, Turn Signals, Flasher Module, Wiring Diagrams, Troubleshooting |
| Electronic System (Stack Command) | 535-582 | ECU Connections, Stack Patterns, Machine Interlocks, Input and Output Tests, Proximity Sensors, Troubleshooting |
| Engine | 583-732 | Engine Specifications, Tightening Torques, Clearances, Engine Removal and Installation, Cylinder Head, Crankshaft, Valve Train |
| Fuel and Injection System | 733-764 | Fuel Tank, Lift Pump, Fuel Filters, Injection Pump, Injection Timing, Injectors |
| Air Intake and Exhaust | 765-796 | Air Filter Elements, Filter Cleaning, Turbocharger, Intercooler, Intake Manifold, Exhaust Back Pressure, Muffler, Exhaust Manifold |
| Engine Coolant System | 797-842 | Cooling Circuit, Cooling Fan, Fan Motor, Radiator, Cooling Assembly, Troubleshooting |
| Lubrication and Starting | 843-856 | Oil Pressure, Engine Oil Capacity, Oil Pump, Oil Cooler, Starter Specifications, Starter Removal and Installation |
| Power Train | 857-918 | Front and Rear Driveline, Allison Transmission, Gear Ratios, Transmission Removal and Installation, Performance Troubleshooting |
| Front Axle | 919-950 | Wheel Lug Nuts, Wheel Bearings, Steering Knuckle, Kingpin Bushings, Axle Beam, Troubleshooting |
| Rear Axle | 951-1040 | Axle Specifications, Noise and Vibration Diagnosis, Differential Gears, Pinion Bearings, Electric Shift Unit, Lubrication |
| Steering | 1041-1146 | Hydraulic Circuit, Caster and Camber, Toe-In, Drag Link, Tie Rod, Steering Column, TRW TAS40 Steering Gear Service |
| Service and Parking Brakes | 1147-1226 | Hydro-Max Booster, Master Cylinder, Front and Rear Disc Brakes, Brake Bleeding, Leak Testing, Parking Brake |
| Suspension | 1227-1232 | Front and Rear Suspension, Leaf Springs, U-Bolts, Spring Bushings |
| Frame and Shields | 1233-1252 | Frame Torques, Frame Rails, Cab Removal, Engine Shield, Front Shield, Bumper, Radiator Screen Door |
| User Controls and Seat | 1253-1324 | Seat Adjustments, Air Suspension, Mirrors, Console Controls, Radio, Instrument Gauges, Wiring Tests |
| User Platform | 1325-1350 | Windshield Wiper, Cab Pressurization, Cab Suspension, Floor and Foot Controls, Platform Steps, Cab Door Latch |
| Environmental Control | 1351-1432 | Heating, Air Conditioning, Compressor, Condenser, Evaporator, Refrigerant Service, Pressure Switches, Diagnostic Charts |
| Safety, Decals and Plates | 1433-1452 | Safety Decals, Emergency Exit, Safety Gate, Seat Belt, Second Table Safety Prop, Identification Plates |
| Crop Processing: Picking, Storing and Unloading | 1453-1560 | Bale Loader, Cross-Conveyor, First Table, Tie Spikes, Second Table, Load Rack, Rolling Rack, Push-Off Feet |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Hydraulic reservoir capacity | 72 L (19 gal) | p. 245 |
| Hydraulic system capacity | 94.6 L (25 gal) | p. 245 |
| Engine oil capacity, including filter, approximately | 13.2 liters (14 quarts) | p. 847 |
| Fuel tank capacity | 75 gallons | p. 734 |
| A/C refrigerant charge | 2.2 lbs. of R-134a | p. 1375 |
| Motor relief (MRV) | 159 bar (2300 psi) | p. 245 |
| Second table relief (STRV) | 145 bar (2100 psi) | p. 245 |
| Rolling rack relief (RRRV) | 76 bar (1100 psi) | p. 245 |
| Load rack counterbalance valve setting | 210 bar (3000 psi) | p. 245 |
| Steering gear relief valve setting | 1850 PSI (127 bar) | p. 1069 |
| Hot engine oil pressure at idle | 1.2 bar (17.4 PSI) | p. 845 |
| Hot engine oil pressure at peak RPM | 3.8 bar (55.1 PSI) | p. 845 |
| Front wheel lug nut torque | 542 N⋅m (400 ft-lbs) | p. 921 |
| Front axle U-bolt nut torque, dry | 365 N⋅m-395 N⋅m (270 ft-lbs-290 ft-lbs) | p. 1230 |
| Front axle U-bolt nut torque, lubricated | 310 N⋅m-340 N⋅m (230 ft-lbs-250 ft-lbs) | p. 1230 |
| Bale loader motor speed | 260 RPM @ 2450 engine RPM | p. 117 |
| Cross-conveyor motor speed | 123 RPM @ 2450 engine RPM | p. 117 |
| Transmission weight | 150 kg (330 lb) | p. 874 |
New Holland BW28, BW38 Common Problems This Manual Covers
Open-center (gear pump) system: no hydraulic functions will operate
If nothing moves at all on the open-center side, suspect a plugged screen before you condemn the gear pump. Pull the screen and clean it. The Primary Hydraulic Power System chapter shows the filtration layout and the pressure tests to run once oil is flowing again.
Manual Section: Primary Hydraulic Power System - Troubleshooting p. 240First table delivers in one mode but not the other
If the first table works in one mode and dies in the other, the Picking troubleshooting chart points to an electronic problem. Go to the Electronic System (Stack Command) chapter and run the input and output tests. Check the proximity sensors and interlocks for that mode before you replace any valves.
Manual Section: Crop Processing - Picking - Troubleshooting p. 1515Second table rises too slowly
A second table that creeps up points to low oil pressure. Check the STR relief valve against its 145 bar (2100 psi) setting with a gauge on the circuit. The Picking troubleshooting chart and the Primary Hydraulic Power System pressure testing section show where to tee in and what to look for.
Manual Section: Crop Processing - Picking - Troubleshooting p. 1519Load rack rises too slowly
If the load rack is slow coming up, look for binding in the spool or the control linkage before you go chasing pressure. Work the linkage by hand, find the tight spot and clear it so the spool shifts its full travel. The Storing and Handling troubleshooting chart walks you through it.
Manual Section: Crop Processing - Storing and Handling - Troubleshooting p. 1540Frequently Asked Questions
Which New Holland bale wagons does this repair manual cover?
It covers the BW28 and BW38 bale wagons. It is the complete repair manual, part # 87693295, and comes as seven books. The two machines differ at the front: the BW28 has an auxiliary first table and two tie spike positions, while the BW38 has three tie spike positions. p. 1
What are the New Holland BW28, BW38 hydraulic reservoir and system capacities and the second table relief setting?
The hydraulic reservoir holds 72 L (19 gal) and the full hydraulic system holds 94.6 L (25 gal). The second table relief (STRV) is set at 145 bar (2100 psi). p. 245
How much engine oil does the New Holland BW28, BW38 take and what hot oil pressure is specified?
With the filter, the engine takes about 13.2 liters (14 quarts) of oil. With the oil hot, pressure should be 1.2 bar (17.4 PSI) at idle and 3.8 bar (55.1 PSI) at peak RPM. p. 847
Which transmissions are covered?
Both Allison automatics are covered. Wagons prior to PIN Y7B665500 have the Allison WT2000, and wagons after it have the Allison 2500RDS. The transmission weighs 150 kg (330 lb). p. 874
Does the manual include hydraulic and electrical schematics?
Yes. The primary hydraulic power system chapter has a hydraulic system diagram plus function diagrams such as bale loader up. It also has electrical schematics for the main manifold, the hydraulics and the fan relay. The lighting chapter has its own wiring diagrams. p. 73
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