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Part of the New Holland Repair Manuals.
This factory manual (OEM #604.66.011.00) runs to 216 pages and covers the full 1992-1999 baler lineup: D1010, D1210, 4860, 4880, 590, and 595, plus every CC and S variant. Factory specifications spell out each model configuration, backed by hydraulic schematics for the bale density circuit and complete wiring diagrams for the electronic Bale Command density control. Exploded views break down every major assembly. Troubleshooting digs into baler operating faults and density control diagnostics, with warning symbol and alarm descriptions plus the automatic lubrication circuit. Set the needle carriage supports to 20 daNm, dial overlap timing to 0 mm (up to 60 mm of delay is allowed on silage), and check the shuttle feeder springs at 280 mm buckle-to-buckle. When the knotters misfire and bale density wanders, this is the factory answer, not a forum guess. Bookmarked by section, so it opens fast on a tablet at the machine.
What's Inside This New Holland D1010 & variants Repair Manual
| System | Pages | Key Topics |
|---|---|---|
| Specifications | 5-30 | Definition of Baler Models, Machines Before S’98 Without CropCutter, Machines From S’98 Onwards + S’97 CropCutters, Torque Table for Standard Metric Hardware |
| Cinematics | 31-35 | Description and Specifications of the Various Elements (Tractor P.T.O., Sliding U-Joint P.T.O. Shaft, Main Safety Slip Clutch, Flywheel, Main Gear Box, Crank Arm, Plunger, Pick-Up, Centering Stub Augers, Packer Assembly, Packer Cutter, Pick-Up Safety Slip Clutch, Packer Safety Slip Clutch, Rotor Cutter, Hydraulic Power Pack and Supply System, Stuffer Assembly, Stuffer Brake, Knotter Drive Shaft, Knotters, Needle Brake) |
| Hook-Up | 36-46 | Low Hitch Requirements Tractor, High Hitch Requirements Tractor |
| Main Slip Clutch - Flywheel | 47-51 | Main Slip Clutch (D1010/4860, D1210/4880, Overview), Flywheel Shearbolt (D1010/4860, D1210/4880), Flywheel |
| Transmission | 52-72 | Main Gearbox, Nh Breganze Built Gearbox (Recommended Oils, Important) |
| Packer (Non Cropcutter Units) | 73-76 | Packer Drive From the Gearbox, Safety Device, Before Season ’98 (Bondioli Slip Slutch), S ’98 Onwards (in House Made Slipclutch), Fitting Packer Fingers to Crankshaft Pins |
| Pick-Up | 77-79 | Drive Train, Pick-Up Lift and Flotation System (Suspension), Working Position, Transport Position |
| Stuffer | 80-96 | Principle of Synchronized Stuffing, Stuffer Shaft Assembly (Only Valid Before Season ’96, Season ’96 Onwards + Retrofitted Old Ones, Stuffer at Rest, Of the Stuffer When Tripped) |
| Plunger/Bale Chamber | 97-101 | Removal of Plunger |
| Knotters | 102-128 | Double Knot Operation (Patented), Knotter Assembly (4880/D1210), Knotter Assembly Stacking (4860/D1010), Adjustment of Knotters/Needles |
| Bale Density Hydraulic Circuit | 129-136 | Hydraulic Power Pack Description, Operation, Specifications of Hydraulic Components |
| Electronic Circuitry - Sensor Housing | 137-189 | Operating Principle of Electronic Bale Density System, Operator’s Control/Display Panel, Operation of the Control/Display Panel, Programming Various Operating Parameters |
| Electrical Circuit for Roadlighting | 190-192 | Tractor Electrical Equipment |
| Automatic Lubrication | 193-203 | Lubrication Circuit, Oil Pump, The Metering Units, How to Prime and to Bleed the System, Troubleshooting, Practical Hints Automatic Lubrication |
| CropCutter | 204-216 | D1010Cc, Drive, Assembly Drive Shaft Connected to the Main Georbox, Slipclutch, Tensioner for Chain, Packer Cutter, Knife Bank, Lining Up From Knives with Packer Crank |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Needle carriage supports torque | 20 daNm | p. 30 |
| Needle overlap timing (value as close as possible) | 0 mm | p. 114 |
| Needle overlap timing (permissible delay for silage) | up to 60 mm | p. 114 |
| Shuttle feeder springs length (buckle to buckle) | 280 mm | p. 90 |
| Load transducer preload (amplified voltage) | 1.6 Volts | p. 164 |
| Load transducer preload (load for model 4880/D1210) | 3000 daN | p. 164 |
| Distance between 2nd roller on needle and scraper (related to twine disc) | between 1.5 and 3 mm | p. 122 |
| Bill hook tongue tension (load required to raise) | 4 to 9 daN | p. 112 |
| Clearance between stripper arm and bill hook tip (at maximum stroke) | minimum 15 mm | p. 113 |
| Knife arm upper twine tension | 10 to 12 daN | p. 113 |
| Knife arm lower twine tension | 12 to 14 daN | p. 113 |
New Holland D1010 & variants Common Problems This Manual Covers
New Holland 4880 electronic bale density system indicator light stays on or reads incorrectly p. 164
Check transducer wiring for damage or moisture ingress, then measure resistance between pins 1 and 4: the correct reading is approximately 352 ohms (page 171). Verify the amplified preload voltage reads 1.6 Volts; on the 4880/D1210, this requires 3000 daN applied load (page 164). Under zero load, confirm output voltage is between 0 and 0.5 mV (page 173).
Manual Section: Electronic Circuitry - Sensor HousingKnotter produces broken knots or mis-ties, twine ends not held after bale is ejected p. 112
Inspect the billhook for wear and check tongue tension: use a spring scale to confirm it lifts at 4 to 9 daN (page 112). Measure the gap between the stripper arm and bill hook tip at maximum stroke; minimum clearance is 15 mm (page 113). Polish all rough contact surfaces on the billhook and wiper before reassembling.
Manual Section: KnottersHay dogs seize up or fail to pivot, won't hold crop during the plunger stroke p. 90
Remove the hay dog assembly and check all pivot pins for corrosion or binding; clean and lubricate each pivot point. Inspect the springs: buckle-to-buckle length should measure 280 mm (page 90), and replace any spring that is collapsed or broken. Reinstall the dogs and verify free movement through the full plunger stroke before returning to service.
Manual Section: StufferNeedle timing drifts after a baler jam or hard plug, knots become inconsistent p. 114
Examine needle timing after any jam. At top dead centre, needle height must be 130 mm (page 125). Check guide lever arm offset from needle rollers: correct clearance is 3 mm (page 115). Confirm the safety linkage has at least 1 mm clearance (page 126), and reset overlap timing as close to 0 mm as possible for dry hay, or up to 60 mm for silage (page 114).
Manual Section: KnottersBaler produces loose or unevenly packed bales that won't hold shape after ejection p. 164
Verify the load transducer preload voltage reads 1.6 Volts at the correct applied load for your model (page 164). Inspect the hydraulic power pack for leaks or low fluid. If density still varies, test pin resistance: pins 1 and 4 should measure approximately 352 ohms (page 171), and under zero load output voltage must fall between 0 and 0.5 mV (page 173).
Manual Section: Electronic Circuitry - Sensor HousingFrequently Asked Questions
How do I reset the monitor or fault display on a New Holland big square baler?
Press the "ESCAPE" key to clear the "stuffer shearbolt", "load transducer", and "knotter mistie" alarms from the display screen. Always fix the underlying fault first, before you press "ESCAPE". To reset the daily bale count, press and hold the "RESET" key for approximately 1.5 seconds.
What do New Holland baler error codes mean on D1010, D1210, 4860, or 4880 models?
The New Holland baler models D1010, D1210, 4860, or 4880 do not display numerical error codes but rather specific warning symbols and full-screen alarms on the graphic display panel. These include warnings for slipping of the packer safety slip clutch and knotter misties, and "STOP" alarms for conditions like flywheel brake engaged, stuffer shearbolt failure, load transducer malfunction, or multiple knotter misfunctions.
How do I clear a fault code on a New Holland 4860S or 4880S baler?
On models like the 4860S or 4880S, the "ESCAPE" key clears the "stuffer shearbolt", "load transducer", and "knotter mistie" alarms from the screen. Correct the underlying fault first; pressing "ESCAPE" before that only invites repeat trouble.
What are the most common problems with New Holland big square balers?
Common problems on New Holland big square balers, as indicated by the electronic display, include slipping of the packer safety slip clutch, knotter misties, flywheel brake engaged, stuffer shearbolt failure, load transducer malfunction, and general knotter misfunction. Additionally, automatic lubrication issues such as low or excessive oil consumption and dry bearings are covered in troubleshooting.
What format is this manual in?
Immediate download of the complete 216-page searchable Repair Manual. Open it on any device: a laptop at your desk or a phone out in the field.
Am I able to print pages from this manual?
Yes, print as many copies as you want; there are no restrictions. Plenty of mechanics print just the section they need and carry it to the shop floor.
Are electrical wiring diagrams included in this New Holland D1010 & variants?
Yes, this New Holland D1010 & variants Repair Manual includes complete electrical wiring diagrams, wire routing, and connector pinouts.
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